Method of manufacturing tampons

ABSTRACT

A method of manufacturing a tampon includes transporting a web of material in a machine direction. The web of material has a base web and an absorbent web. The absorbent web has a free end and a bonded end wherein the bonded end is bonded to the base web. At least the free end of the absorbent web of the web to is controlled to inhibit movement of the absorbent web relative to the base web. The web of material is cut into discrete web segments while controlling at least the free end of the absorbent web. The discrete web segments is bonded to a substrate.

BACKGROUND

Currently, there are two basic types of tampons used for femininehygiene. The first type is a digitally insertable tampon which isdesigned to be inserted directly by the user's fingers. The second typeis an applicator style tampon which is designed to be inserted with theaid of an applicator. Both types are usually made by folding or rollingrectangular strips of absorbent material into a blank and thencompressing the blank into a cylindrically-shaped pledget. The pledgetmay or may not have a cover. In both types, a withdrawal string can beattached to the pledget. The combination of a pledget and a withdrawalstring is considered a useable tampon product. The tampon can then bewrapped and packaged for sale. In the applicator style tampon, thetampons can be assembled into an applicator prior to being wrapped andpackaged.

Tampons work by acquiring vaginal fluids, including menses, at theinterface between the tampon and vaginal wall. To ensure this contact,current tampons alter the vagina immediately upon insertion. Thisalteration contributes to early premature, “by-pass” leakage. After thetampon absorbs the vaginal fluids, including menses, most tampons beginto expand uniformly and globally, further contributing to this leakage.At the same time, the tampon begins to become more flexible andconformable to allow for a better global/macro fit to the vagina. Thispredetermined and uniform tampon response that drives this global/macroexpansion is governed by the tampon construction and materials.

Even when fluid is acquired locally and the deformational forces on thetampon by the vaginal environment are applied locally, with currenttampons the construction or materials of the tampons inhibits orconstrains their capacity to expand or adapt to give a local/micro fit.These constructions and materials force the entire tampon to respond tothese local fluid acquisition and deformational forces through materialconnectivity or material stiffness.

When attempts are made to allow for more local adaptation in tamponconstructions, the constructions do not acquire the fluids well becauseof inadequate contact area because they cannot match the local contoursof the vaginal wall or are not conformable enough to adapt to thewomen's individual local contours (e.g. folds and convolutions) found onthe vaginal wall. In addition, these attempts create integrity issueswith the tampons that lead to portions of the tampon remaining withinthe vagina after tampon removal. This inadequate contact is especiallytrue during the wiping action of the vagina by the tampon when thetampon is inserted and removed.

Current tampon construction processes construct these inadequate tamponsthat have this predetermined and uniform tampon response. They createthese constraints, inadequate contact area, and integrity issues inorder to drive this predetermined and uniform tampon response and,therefore, limit the tampon from effectively responding locally. Newconstruction processes are needed to construct tampons that overcome theinadequacy of current tampons.

There remains a need for a tampon that responds locally to meet theindividual protection needs of women and processes to make such tampons.There remains a need for a tampon that prevents leakage of body fluidafter being inserted into a woman's vagina. There remains a need for atampon that provides efficient utilization of the entire tamponstructure during use. There remains a need for a tampon that provides acustomized fit to the anatomy of a woman's vaginal cavity. There remainsa need for a tampon that can deform and come into contact with the foldsand convolutions of the walls of the vaginal cavity and acquire anycontacted fluid.

One potential solution to these needs is to provide a tampon having aplurality of relatively small, discrete contact elements that areadapted to contact the folds and convolutions of the walls of thevaginal cavity and thereby reduce the potential for leakage of bodyfluid (e.g., menses) past the tampon. Although incorporating theplurality of discrete contact elements into a tampon will potentiallyreduce tampon leakage, the process to incorporate them into a usabletampon presents many significant challenges.

One of these challenges is meeting the Food and Drug Administration(FDA) guidelines for a Class 2 medical device. These guidelines are inplace to prevent defective tampons from causing adverse reaction with aconsumer which includes, for example, increased risk of Toxic ShockSyndrome (TSS) and vaginal infections. Three of these FDA guidelinesrelate to absorbency, fiber shedding (residual fiber retention) andtampon integrity. The presence of these discrete contact elements on thetampon can impact the tampon performance in respect to each and everyone of these guidelines. To minimize the potential of the discretecontact elements negatively impacting tampon performance, steps have tobe taken during manufacturing to prevent tampon process damage. Tamponprocess damage can potentially alter the performance of the tampon fromit design requirements and includes, for example, lost contact elements,incorrectly formed or otherwise damaged contact elements, and weakenedcontact elements.

As used herein, tampon process damage is any alteration to the tamponthat is caused by the process to create a damaged tampon. This damagecan include missed or inappropriate placed contact elements and surfaceprocess damage. When this damage causes the tampon to be outside the FDAguidelines, the tampon is a said to be a defective tampon. Surfaceprocess damage is any alteration to a surface that is caused by theprocess to create a damaged surface. Each surface of the tampon isdesigned to have certain design characteristics. When any of thesedesign characteristics vary significantly from target values, thesurface is said to be a damage surface. These design characteristicsincludes surface size, shape, configuration, and absorbency andmechanical characteristics or properties.

Examples include missing and malformed surface and deterioratedabsorbency or mechanical properties. A malformed surface includesimproperly sized, shaped, cut, bent, and folded surface and especiallymalformations that alter the surface contact area with the vaginalsurfaces. A deteriorated absorbency or mechanical property includesreduced wettability, permeability, and mechanical strength andespecially deteriorations that alter the surfaces ability to conform tovaginal surfaces and acquire, intake, and distribute vaginal fluids.

The process used to manufacture the discrete contact elements of thetampon must be able to make the contact elements consistently andreproducibly at high speeds and ensures that only tampons withoutsignificant process and/or surface damage are sold to consumers. Thus,there remains a need for a tampon processes capable of consistently andreproducibly manufacturing tampons with discrete contact elements athigh speeds and without significant process and/or surface damage.

BRIEF DESCRIPTION

In one aspect, a method of manufacturing a tampon generally comprisestransporting a web of material in a machine direction. The web ofmaterial comprises a base web and an absorbent web. The absorbent webhas a free end and a bonded end wherein the bonded end is bonded to thebase web. At least the free end of the absorbent web of the web iscontrolled to inhibit movement of the absorbent web relative to the baseweb. The web of material is cut into discrete web segments whilecontrolling at least the free end of the absorbent web and the discreteweb segments are bonded to a substrate.

In another aspect, a method of manufacturing a tampon generallycomprises transporting a first web of material in a machine directionand transporting a second web of material in the machine direction. Thesecond web of material comprises a base web and an absorbent web. Theabsorbent web has a free end and a bonded end wherein the bonded end isbonded to the base web. At least the free end of the absorbent web ofthe second web is controlled to inhibit movement of the absorbent webrelative to the base web. The second web of material is cut intodiscrete web segments while controlling at least the free end of theabsorbent web. The discrete web segments are bonded to the first web ofmaterial at predetermined intervals.

In yet another aspect, a method of manufacturing a tampon generallycomprises transporting a web of material in a machine direction. The webof material comprises a base web and an absorbent web. The absorbent webhas a free end and a bonded end wherein the bonded end is bonded to thebase web. The free end includes a plurality of slits. At least the freeend of the absorbent web of the web is controlled to inhibit movement ofthe absorbent web relative to the base web. The web of material is cutin the cross machine direction to form discrete web segments whilecontrolling at least the free end of the absorbent web. The discrete websegments are bonded to a substrate.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of a tampon in acompressed configuration.

FIG. 2 is a perspective view of an embodiment of a nonwoven ribbon.

FIG. 3 is a perspective view of an embodiment of a fleece.

FIG. 4 is a perspective view of an embodiment of an absorbent structure.

FIG. 5 is a perspective view of an embodiment of an absorbent structure.

FIG. 6 is a perspective view of an embodiment of an absorbent structure.

FIG. 7 is a perspective view of an embodiment of an absorbent structure.

FIG. 8 is a perspective view of an embodiment of an absorbent structure.

FIG. 9 is a side view of an embodiment of an absorbent structure.

FIG. 10 is a perspective view of an embodiment of a tampon in anactivated configuration.

FIG. 11 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 12 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 13 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 14 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 15 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 16 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 17 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 18 is a side view of an embodiment of an absorbent structure.

FIG. 19 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 20 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 21 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 22 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 23 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 24 is a perspective view of an embodiment of an absorbent structurewith at least one contact element.

FIG. 25 is a perspective view of an embodiment in which a cover isbonded to a blank.

FIG. 26A is an end view of an embodiment in which a cover is bonded to ablank.

FIG. 26B is an end view of an embodiment in which a cover is bonded to ablank.

FIG. 27 is a side view of an embodiment of a tampon wherein the coverdefines a skirt.

FIG. 28 is a perspective view of an embodiment of a tampon in anactivated configuration.

FIG. 29 is a perspective view of an embodiment of a method ofmanufacturing an absorbent structure.

FIG. 30 is a perspective view of an embodiment of a method ofmanufacturing an absorbent structure.

FIG. 31 is a schematic of one suitable embodiment of an apparatus formaking a cover material used in forming the tampon.

FIG. 32 is an enlarged schematic of a portion of the apparatus of FIG.31.

FIG. 33 is an enlarged schematic of another portion of the apparatus ofFIG. 31.

FIG. 34 is a cross-section showing a web of absorbent material overlayedonto a web of base material.

FIG. 35 is a cross-section similar to FIG. 34 but showing the web ofabsorbent material bonded to the web of base material.

FIG. 36 is a fragmentary top view of the webs of FIG. 35.

FIG. 37 is a cross-section similar to FIG. 35 but showing the web ofbase material being folded to cover the web of absorbent material.

FIG. 38 is a cross-section similar to FIG. 37 but showing outer portionsof the webs being folded inward.

FIG. 39 is a fragmentary top view of the webs of FIG. 38 with the foldedouter portions of the webs being bonded.

FIG. 40 is a fragmentary top view similar to FIG. 39 but showing inneredges of the folded outer portions of the webs being bonded.

FIG. 41 is a top view of the webs illustrating slits cut into the web ofabsorbent material.

FIG. 42 is a schematic of another suitable embodiment of an apparatusfor making a cover material used in forming the tampon.

FIG. 43 is an enlarged schematic of a portion of the apparatus of FIG.42.

FIG. 44 is an enlarged schematic of another portion of the apparatus ofFIG. 42.

FIG. 45 is a cross-section of a pair of webs of absorbent materialpassing through the apparatus and having the outermost one-third of eachof the webs folded inward.

FIG. 46 is a cross-section showing the pair of webs of FIG. 45 overlayedonto and bonded to a web of base material.

FIG. 47 is a fragmentary top view of the webs of FIG. 46.

FIG. 48 is a cross-section showing the outer portions of the webs beingfolded inward.

FIG. 49 is a fragmentary top view of the webs of FIG. 48 with the foldedouter portions of the webs being bonded.

FIG. 50 is a fragmentary top view similar to FIG. 49 but showing inneredges of the folded outer portions of the webs being bonded.

FIG. 51 is a schematic of one suitable embodiment of an apparatus formaking the tampon.

FIG. 52 is a cross-section of a vacuum conveyor being used to hold downand transport a web of cover material.

FIG. 53 is a fragmentary top view of the vacuum conveyor and web of FIG.52.

FIG. 54 is a fragmentary top view of the web of cover material overlyinga web of fleece.

FIG. 55 is a perspective illustrating the web of cover material beingbonded to the web of fleece at an assembly station of the apparatus ofFIG. 51.

FIG. 56 is an end view illustrating the web of cover material being cutto form slits therein at a cutting station of the apparatus.

FIG. 57 is a top view of the webs of cover material and fleece passingthrough the apparatus and having a withdrawal aid attached thereto.

FIG. 58 is a side view of a transfer assist device for facilitating thetransfer of a softwind.

DETAILED DESCRIPTION OF THE DRAWINGS

The tampon of the current disclosure can be inserted above the introitalregion of a woman's vagina, can intercept the fluid flow of menses,blood, and other body fluids, and can prevent the fluid from exiting thevagina. While the pledgets and tampons of the current disclosure aredescribed for use as a menstrual device, it will be readily apparentthat the pledgets and tampons can also be used as any other suitablevaginal insert, such as a pessary. Likewise, while the pledgets andtampons of the current disclosure are generally described as being“absorbent,” it will be readily apparent that the pledgets and tamponsmay be coated or otherwise treated to be partially or completelynon-absorbent.

In an embodiment, the pledget and tampon of the current disclosure canhave a contact element. In an embodiment, the contact element can allowthe pledget and the tampon to respond locally to the changes in thevaginal environment and can effectively acquire fluid locally toaccommodate the uniqueness of a woman's vaginal environment and herperiod.

A non-limiting embodiment of a tampon 10 of the current disclosure isillustrated in FIG. 1. The tampon 10 can be inserted into a woman'svaginal cavity to prevent menses from exiting the vaginal opening bycontacting and absorbing the flow of menses. The term “menses,” as usedherein, includes blood, tissue debris, and other bodily fluids emittedfrom the vaginal opening. The tampon 10 can have a compressed, generallycylindrical shaped pledget 12 and a withdrawal aid 14. In someembodiments, the generally cylindrical shape of the pledget 12 can havea cross-section that can be at least one of an oval, circle, square,rectangle, or any other cross-sectional shape known in the art. The term“cross-section” refers herein to the plane which extends laterallythrough the tampon 10, and which is orthogonal to the longitudinal axis16 of the pledget 12, and consequently, of the tampon 10. The tampon 10can have an insertion end 18 and a withdrawal end 20. The tampon 10 canhave a length 22 wherein the length 22 is the measurement of the tampon10 along the longitudinal axis 16 originating at one end (insertion orwithdrawal) of the tampon 10 and ending at the opposite end (insertionor withdrawal) of the tampon 10. In some embodiments, the tampon 10 canhave a length 22 from about 30 mm to about 80 mm. The tampon 10 can havea width 24, which unless otherwise stated herein, can correspond to thegreatest cross-sectional dimension along the longitudinal axis 16 of thetampon 10. In some embodiments, the tampon 10 can have a compressedwidth 24 prior to usage from about 2, 5, 8, 10, 12, or 14 mm to about 20or 30 mm. The tampon 10 may be straight or non-linear in shape, such ascurved along the longitudinal axis 16.

As noted above, the tampon 10 can have a pledget 12. The pledget 12 canbe formed from a blank 28, such as a softwind, wherein the blank 28 canbe formed from a fleece 30. The fleece 30 can have an absorbentstructure 34 which can be a single layer of a fibrous material or can bemultiple layers of fibrous material. In an embodiment, an absorbentstructure 34 can be formed of at least two layers of fibrous materials.The absorbent structure 34 can be manufactured via processes such as,for example, a multi-bank laydown, bonding pre-formed layers together,or a combination thereof. Such processes can produce a nonwoven ribbon32 having an absorbent structure 34 of a single layer or multiple layersof fibrous materials. In an embodiment, the nonwoven ribbon 32 can beseparated into individual units of fleece 30, wherein each unit offleece 30 can have the absorbent structure 34.

In an embodiment in which the absorbent structure 34 is multi-layered,the absorbent structure 34 can have at least 2, 3, 4, 5, 6, or 7 layersof fibrous material. In an embodiment in which the absorbent structure34 is multi-layered, a layer can be identical to another layer, can bedifferent from another layer, or can be identical to at least one otherlayer and can be different from at least one other layer. In anembodiment in which an absorbent structure 34 is multi-layered and atleast one layer is different from another layer, the layers can bedifferent from each other by at least 1, 2, 3, 4 or 5 aspects.Non-limiting examples of aspects of differences can include density,thickness, type of fibrous material in a layer, amount of fibrousmaterial in a layer, hydrophilic/hydrophobic characteristics, andstrength/integrity characteristics (which can include reinforcingfibrous materials).

In an embodiment in which the absorbent structure 34 is multi-layered,the absorbent structure 34 can be manufactured by bonding at least twopre-formed layers together. In such an embodiment, the pre-formed layerscan be brought into contact with each other and bonded together by anysuitable method. In such an embodiment, the bonded layers can then bebonded to at least one additional layer. The at least one additionallayer can be pre-formed or can be a laid down fibrous material.

In an embodiment in which the absorbent structure 34 is multi-layered,the absorbent structure 34 can be manufactured via a process such as amulti-bank fibrous material laydown. In such a process, fibrous materialin a first bank can be laid down to form a first layer and fibrousmaterial in a second bank can be laid down onto the first layer andformed into a second layer. The second layer can then, if desired, bebonded to the first layer. In an embodiment, fibrous material in atleast one additional bank can be laid down onto the prior layers andformed into at least one additional layer if so desired. The additionallayer(s) can be bonded to the prior formed and bonded layers. In anembodiment, a pre-formed layer can be bonded to the formed and bondedlayers.

FIG. 2 provides a non-limiting illustration of a nonwoven ribbon 32which can have a multi-layer absorbent structure 34 of at least twolayers, such as layers 36 and 38. The nonwoven ribbon 32 can bemanufactured via either a multi-bank fibrous material laydown method,via bonding of pre-formed layers, or via a combination of the describedmethods. It is to be understood that while the description and figuresherein generally illustrate a nonwoven ribbon 32, an absorbent structure34 and/or a fleece 30 having two layers, such as layers 36 and 38, anonwoven ribbon 32, an absorbent structure 34 and/or a fleece 30 canhave more than two layers and the description herein is applicable to anonwoven ribbon 32, an absorbent structure 34 and/or a fleece 30 havingmore than two layers.

In an embodiment, the nonwoven ribbon 32 can have more than two layers.In an embodiment, a layer(s), such as layer(s) 36 and/or 38, can behydrophobic or hydrophilic. In an embodiment, a layer(s), such aslayer(s) 36 and/or 38, can be treated with a surfactant or othermaterial to make the layer(s) hydrophilic or to make the layer(s) morehydrophilic. As will be described herein, in a nonwoven ribbon 32 havingmore than one layer, the layers, such as layers 36 and 38, can be incommunication with each other. In an embodiment, the layers, such aslayers 36 and 38, can be in communication with each other and can bebonded to each other. The terms “bonded” or “bonding” refer herein tothe joining, adhering, connecting, attaching or the like of twoelements. Two elements will be considered bonded together when they arejoined, adhered, connected, or attached directly to one another orindirectly to one another, such as when each is directly joined,adhered, connected or attached to intermediate elements. The bonding canoccur by any method deemed suitable including, but not limited to,adhesives, heat bonding, vibration energy, mechanical bonding, chemicalbonding, vacuum bonding, ultrasonic bonds, thermal bonds, pressurebonds, mechanical entanglement, hydroentanglement, microwave bonds, orany other conventional technique. The bonding can be continuous or itcan be intermittent.

Each layer, such as layers 36 and 38, can be constructed from fibrousmaterials, such as fibrous materials 40 and 42, respectively. In anembodiment, the fibrous materials can include absorbent fibers. Thefibrous materials can include, but are not limited to, natural andsynthetic fibers such as, but not limited to, polyester, acetate, nylon,cellulosic fibers such as wood pulp, cotton, rayon, viscose, LYOCELL®such as from Lenzing Company of Austria, or mixtures of these or othercellulosic fibers. Natural fibers can include, but are not limited to,wool, cotton, flax, hemp and wood pulp. Wood pulps can include, but arenot limited to, standard softwood fluffing grade such as CR-1654 (USAlliance Pulp Mills, Coosa, Ala.). Pulp may be modified in order toenhance the inherent characteristics of the fibers and theirprocessability. Crimping can be imparted to the fibers by any meansdeemed suitable by one of ordinary skill. Curl may be imparted to thefibers by suitable methods such as, for example, chemical treatment ormechanical twisting. Curl can be imparted before crosslinking orstiffening. Pulps may be stiffened by the use of crosslinking agentssuch as formaldehyde or its derivatives, glutaraldehyde,epichlorohydrin, methylated compounds such as urea or urea derivatives,dialdehydes such as maleic anhydride, non-methylated urea derivatives,citric acid or other polycarboxylic acids. Pulp may also be stiffened bythe use of heat or caustic treatments such as mercerization. Examples ofthese types of fibers include NHB416, which is a chemically cross-linkedsouthern softwood pulp fiber which enhances wet modulus, available fromWeyerhaeuser Corporation of Tacoma, Wash. Other non-limiting examples ofuseful pulps are debonded pulp (NF405) and non-debonded pulp (NB416)also from Weyerhaeuser. HPZ3 from Buckeye Technologies, Inc. of Memphis,Tenn., is an example of a fiber that has a chemical treatment that setsin a curl and twist, in addition to imparting added dry and wetstiffness and resilience to the fiber. Another suitable pulp is BuckeyeHP2 pulp and still another is IP Supersoft from International PaperCorporation. The fibrous materials can include any suitable blend offibers. For example, the fibrous materials can be formed from cellulosefibers such as cotton and rayon. The fibrous materials can be 100 wt %cotton, 100 wt % rayon, or a blend of cotton and rayon. In someembodiments, the cellulose fibers may be modified for super-absorbency.In an embodiment, a layer, such as layer 36 or 38, can havesubstantially the same fibrous material composition as another layer,such as layer 36 or 38. In an embodiment, a layer, such as layer 36 or38, can have a fibrous material composition different from anotherlayer, such as layer 36 or 38.

In an embodiment, the fibrous materials can have a staple length of fromabout 5, 10, 15 or 20 mm to about 30, 40 or 50 mm. In an embodiment, thefibrous materials can have a fiber size of from about 15 microns toabout 28 microns. In an embodiment, the fibrous materials can have adenier of from about 1 or 2 to about 6. Denier is a unit of fineness ofyarn based on a standard of 50 milligrams (mg) for 450 meters of yarn.The fibrous materials can have a circular, bi-lobal or tri-lobalcross-sectional configuration or any other configuration known to thoseskilled in the art. A bi-lobal configuration can have a cross-sectionalprofile which can look like a dog bone while a tri-lobal configurationcan have a cross-sectional profile which can look like a “Y.” In anembodiment, the fibrous materials can be bleached. In an embodiment, thefibrous materials can have a color.

In an embodiment, a layer(s), such as layer(s) 36 and/or 38, can containfibrous materials such as binder fibers. In an embodiment, the binderfibers can have a fiber component which can bond or fuse to other fibersin the layer. Binder fibers can be natural fibers or synthetic fibers.Synthetic fibers can include, but are not limited to, those made frompolyolefins, polyamides, polyesters, rayon, acrylics, viscose,superabsorbents, LYOCELL® regenerated cellulose and any other suitablesynthetic fiber known to those skilled in the art. Non-limiting examplesof polyolefins can include, but are not limited to, polyethylene such asDow Chemical's ASPUN® 6811A linear low density polyethylene, 2553 LLDPEand 25355 and 12350 high density polyethylene. The polyethylenes canhave melt flow rates, respectively, of about 26, 40, 25, and 12.Non-limiting examples of fiber forming polypropylenes can include, butare not limited to, Exxon Chemical Company's ESCORENE® PD 3445polypropylene and Montell Chemical Company's PF304. Another example of afiber can be a bi-component polyethylene sheath and polyester core knownas T255 made by Trevira of Germany. Other non-limiting examples ofmeltable bicomponent fibers can include, but are not limited to, fibersavailable from Unitika of Japan, such as, for example, Unitika MELTY4080, and 6080 fibers, having either polyester sheaths or cores andpolyethylene sheaths or cores. Another example can include, but is notlimited to, fibers available from Fibervisions under the designation ETCBounce fiber line, such as PET/PE fibers of about 2.2 decitex and about40 mm staple fiber length. Non-limiting examples of rayon fibers include1.5 denier Merge 18453 fibers from Accordis Cellulose Fibers Inc. ofAxis, Ala. The fibrous materials can be treated by conventionalcompositions and/or processes to enable or enhance wettability.

In an embodiment, a layer(s), such as layer(s) 36 and/or 38, can containfibrous materials such as cellulosic fibers, such as cotton and rayon.In an embodiment, a layer(s), such as layer(s) 36 and/or 38, can be 100%cotton, 100% rayon, or a blend of cotton and rayon fibers. In anembodiment, a blend of cotton and rayon fibers can be a blend of about15% cotton and about 85% rayon; about 70% cotton and about 30% rayon;about 60% cotton and about 40% rayon; about 25% cotton and about 75%rayon; or a blend of about 6% cotton and about 94% rayon. The blend ofcotton and rayon can be any blend as deemed suitable. In an embodiment,additional fibers such as polyester or other synthetic fibers can beadded to the blend of cotton and rayon to add resilient features orbondability to a layer(s), such as layer(s) 36 and/or 38.

In an embodiment, a layer(s), such as layer(s) 36 and/or 38, can have ablend of viscose and binder fibers. In an embodiment, a blend of viscoseand binder fibers can be a blend of from about 70% viscose to about 95%viscose with the remainder from about 30% to about 5% binder fiber. Inan embodiment, a blend of viscose and binder fibers can be a blend offrom about 85-90% viscose and the remainder from about 15-10% binderfiber. The blend of viscose and binder fibers can be any blend as deemedsuitable.

Various methods known to those skilled in the art can be used to prepareeach layer, such as layers 36 and 38. Such methods can include, but arenot limited to, airlaying, carding, wetlaying, needlepunching,mechanical entanglement, hydroentangling, and any other known methoddeemed suitable by one of ordinary skill. In an embodiment, a bondedcarded web can be made from staple fibers. In such an embodiment, thefibers can be longer than about 20, 30 or 35 mm. The fibers can bepurchased in bales which can be placed in a picker to separate thefibers. The fibers can then be sent through a combing or carding unit,which can further break apart and align the staple fibers in the machinedirection to form a generally machine direction-oriented fibrousnonwoven web. Once the web is formed, it can then be bonded by one ormore of several known bonding methods, such as through air bonding orpattern bonding. In an embodiment, a dry laid web can be made fromstaple fibers. In such an embodiment, the fibers can be about 20 mm orlonger. In dry laying, fibers or tufts of fibers of a first type (e.g.,absorbent fibers and/or binder fibers) can be fed to a first rotatingvacuum drum and fibers or tufts of fibers of a second type (e.g.,absorbent fibers and/or binder fibers) can be fed to a second rotatingvacuum drum. The fibers can then be laid down by suction to form mats offibers. The mats of fibers can be doffed from the vacuum drums andcombed via rotating lickerins. The lickerins can have peripheral teethwhich can comb the fibers from the mat. The combed fibers can be doffedfrom the lickerins via centrifugal force and placed into a fiber mixingand expansion chamber. The mixed fibers can be placed on a vacuum screento form a random fiber web comprising the first and second fiber types.The flow and velocity of each independent fiber stream can be controlledto provide the desired quantity of each fiber type. It is to beunderstood that a layer, such as layer 36 or 38, can be prepared usingthe same method as another layer, such as layer 36 or 38, or using amethod different than another layer, 36 or 38.

In an embodiment, at least one of the layers, such as layers 36 and/or38, can be prepared using an airlaying process. In such an embodiment,the airlaid fibers can contain a first fiber and a second fiber, whereinthe first fiber can be a binder fiber and the second fiber can be anabsorbent fiber.

In an embodiment in which binder fibers are present, the binder fiberscan be activated to create a three-dimensional fiber matrix. In such anembodiment, the activation can be completed by any suitable heating stepincluding, but not limited to, convection heating, through air heating,superheated steam, microwave heating, radiant heating, radio frequencyheating, and the like, and combinations thereof. In some embodiments,the activation can be accomplished by heating the layer(s), such aslayer(s) 36 and/or 38, containing the binder fibers at a temperature offrom about 240° F. to about 428° F. (about 115° C. to about 220° C.) toactivate the binder fibers. It is to be understood that the bondingtemperature selected should be selected based upon the fibrous materialswhich are being bonded together. Without being bound by theory, it isbelieved that during activation, the binder fibers can soften and becometacky and, therefore, bind to adjacent fibers creating athree-dimensional fiber matrix. It is believed that thethree-dimensional fiber matrix can stabilize the layer(s), such aslayer(s) 36 and/or 38, and can create a liquid stable network. It is tobe understood that an additional component or finish can be added to thefibers to facilitate bonding of fibrous materials which are notnecessarily compatible.

In an embodiment, the activation can be followed by a cooling step whichcan utilize any suitable means for reducing the temperature of thelayer(s), such as layer(s) 36 and/or 38. In an embodiment, the layer(s),such as layer(s) 36 and/or 38, can be cooled by allowing the layer(s),such as layer(s) 36 and/or 38, to return to ambient temperature over aperiod of time. In an embodiment, the layer(s), such as layer(s) 36and/or 38, can be cooled by chill rolls, cooling chambers, blowingconditioned air, or the like, and combinations thereof. In anembodiment, the cooling step can occur prior to compression of thelayer(s), such as layer(s) 36 and/or 38, to establish a wet-stablethree-dimensional structure.

In some embodiments, a layer(s), such as layer(s) 36 and/or 38, can befurther manipulated such as, for example, being folded, corrugated, orotherwise processed.

The nonwoven ribbon 32 can be separated into individual units of fleece30. The separation of the nonwoven ribbon 32 into individual units offleece 30 can occur by any suitable method such as stretching,perforating, cutting such as with the use of a die cutter or a knifecutter, and the like. The individual units of fleece 30 can then berolled, stacked, folded, or otherwise manipulated into blanks 28. Theblanks 28 can then be formed into pledgets 12 in any manner deemedsuitable. As a non-limiting example, the blanks 28 can undergocompression to form the pledgets 12.

In various embodiments, the fleece 30 and the resultant pledget 12 canhave any suitable combination and ratio of fibrous material. In anembodiment, the fleece 30 and the resultant pledget 12 can have fromabout 70 to about 95 wt % absorbent fibers and from about 5 to about 30wt % binder fibers. In an embodiment, the fleece 30 and the resultantpledget 12 can have from about 80 to about 90 wt % absorbent fibers andfrom about 10 to about 20 wt % binder fibers. In an embodiment, thefleece 30 and the resultant pledget 12 can have about 85 wt % absorbentfibers and about 15 wt % binder fibers. In an embodiment, the fleece 30and the resultant pledget 12 can have from about 80 to about 90 wt %trilobal viscose rayon fibers and from about 10 to about 20 wt %bicomponent binder fibers. In an embodiment, the fleece 30 and theresultant pledget 12 can have about 85 wt % trilobal viscose rayonfibers and about 15 wt % bicomponent binder fibers. In an embodiment,the fleece 30 and the resultant pledget 12 can have greater than about50, 55, 60, 65, 70, 80, 90, 95, 97, or 99 wt % absorbent fibers.

The fleece 30 can be any size and thickness that can ultimately becompressed into a pledget 12 having a vaginally insertable shape. In anembodiment, the size of the fleece 30 can range from about 40 mm toabout 100, 200, 250 or 300 mm in width and from about 30 mm to about 80mm in length. As described herein, the width of the fleece 30 can bemeasured as the distance between longitudinal edges of the fleece 30 andthe length of the fleece 30 can be measured as the distance betweentransverse edges of the fleece 30. As described herein, the transverseedges of the fleece 30 can be located at the insertion and withdrawalends, 18 and 20, respectively, of a resultant tampon 10. In anembodiment, the overall basis weight of the fleece 30 can range fromabout 15, 20, 25, 50, 75, 90, 100, 110, 120, 135 or 150 gsm to about1,000, 1,100, 1,200, 1,300, 1,400, or 1,500 gsm.

Referring to FIG. 3, a non-limiting example of a fleece 30 isillustrated in which the fleece 30 can have a multi-layer absorbentstructure 34 of two layers, 36 and 38. In the non-limiting exampleillustrated, the first layer 36 can have a first length 44 and a firstwidth 46. The first length 44 can extend from a first transverse edge 48to a second transverse edge 50 of the first layer 36. The first width 46can extend from a first longitudinal edge 52 to a second longitudinaledge 54 of the first layer 36. The first layer 36 can have a firstsurface 56 (illustrated in FIG. 4) and a second surface 58. Similarly,the second layer 38 can have a second length 60 and a second width 62.The second length 60 can extend from a first transverse edge 64(illustrated in FIG. 4) to a second transverse edge 66 of the secondlayer 38. The second width 62 can extend from a first longitudinal edge68 to a second longitudinal edge 70 of the second layer 38. The secondlayer 38 can have a first surface 72 and a second surface 74(illustrated in FIG. 4). In a resultant tampon 10, the transverse edgesof each layer, 36 and 38, can be located at the insertion end 18, thewithdrawal end 20 or, as described herein, a location between theinsertion end 18 and the withdrawal end 20. As a non-limiting examplewith regards to the fleece 30 illustrated in FIG. 3, transverse edges 50and 66 can be located at the insertion end 18 of a resultant tampon 10and transverse edges 48 and 64 can be located at the withdrawal end 20of a resultant tampon 10.

The absorbent structure 34 can be constructed such that one of thesurfaces, 56 or 58, of the first layer 36 can be at least partially in aface to face relationship with one of the surfaces, 72 or 74, of thesecond layer 38. In an embodiment, at least about 25% of one of thesurfaces, 72 or 74, of the second layer 38 can be in a face to facerelationship with one of the surfaces, 56 or 58, of the first layer 36.In an embodiment, at least about 25, 30, 35, 40, 45, 50, 55, 60, 65, 70,75, 80, 85, 90, 95 or 100% of one of the surfaces, 72 or 74, of thesecond layer 38 can be in a face to face relationship with one of thesurfaces, 56 or 58, of the first layer 36. In an embodiment, less than100% of one of the surfaces, 72 or 74, of the second layer 38 can be ina face to face relationship with one of the surfaces, 56 or 58, of thefirst layer 36. In an embodiment, from about 25, 30, 35, 40, 45, or 50%to about 55, 60, 65, 70, 75, 80, 85, 90, 95 or 100% of one of thesurfaces, 72 or 74, of the second layer 38 can be in a face to facerelationship with one of the surfaces, 56 or 58, of the first layer 36.

In the exemplary illustration of FIG. 3, the first and second layers, 36and 38, are illustrated as being substantially coextensive with eachother. In such an embodiment, the first length 44 of the first layer 36can be substantially the same as the second length 60 of the secondlayer 38. The first width 46 of the first layer 36 can be substantiallythe same as the second width 62 of the second layer 38. In the exemplaryillustration of FIG. 3, about 100% of the first surface 56 of the firstlayer 36 can be in a face to face relationship with the second surface74 of the second layer 38. As described herein, a withdrawal aid 14 anda cover 138 can be associated with the fleece 30.

In an embodiment, the fleece 30 can have a multi-layer absorbentstructure 34 in which one of the layers, 36 or 38, can have a lengthand/or width different from the other layer, 36 or 38. Referring toFIGS. 4-8, non-limiting examples of embodiments of absorbent structures34 are illustrated in which one layer, 36 or 38, can have a lengthand/or width different from the other layer, 36 or 38.

FIG. 4 provides an illustration of a non-limiting example of anembodiment of a multi-layer absorbent structure 34 in which the firstlayer 36 can have a first width 46 greater than the second width 62 ofthe second layer 38. As illustrated in FIG. 4, the first length 44 ofthe first layer 36 can be substantially similar to the second length 60of the second layer 38. In the non-limiting example illustrated in FIG.4, the second layer 38 can be bonded to the central region of the firstwidth 46 of the first layer 36. The central region of the first width 46can be the area adjacent a center line 78 of the first width 46 of thefirst layer 36 of the absorbent structure 34. It is to be understoodthat the central region of the first width 46 does not need to be theexact center of the first layer 36, but can be located generally aroundthe center line 78 of the first width 46. In an embodiment, the centralregion of the first width 46 of the first layer 36 can be a positionalong the first width 46 which is a distance 80 that is about 0.35 toabout 0.65 times the first width 46, as measured from eitherlongitudinal edge, 52 or 54, of the first layer 36. It is to beunderstood that the second layer 38 does not have to be bonded to thefirst layer 36 in the central region of the first width 46, but rathercould be bonded to the first layer 36 in an area adjacent to one of thelongitudinal edges, 52 or 54, or at any other position along the firstwidth 46 of the first layer 36 as deemed suitable.

FIG. 5 provides an illustration of a non-limiting example of anembodiment of a multi-layer absorbent structure 34 in which the firstlayer 36 can have a first length 44 greater than the second length 60 ofthe second layer 38. As illustrated in FIG. 5, the first width 46 of thefirst layer 36 can be substantially similar to the second width 62 ofthe second layer 38. In the non-limiting example illustrated in FIG. 5,the second layer 38 can be bonded adjacent to one of the transverseedges, 48 or 50, such as transverse edge 50, of the first layer 36. Itis to be understood that the second layer 38 can be bonded to the firstlayer 36 at any position along the first length 44 of the first layer 36as deemed suitable.

FIG. 6 provides an illustration of a non-limiting example of anembodiment of an absorbent structure 34 in which the first layer 36 canhave a first length 44 greater than the second length 60 of the secondlayer 38. As illustrated in FIG. 6, the first width 46 of the firstlayer 36 can be substantially similar to the second width 62 of thesecond layer 38. In the non-limiting example illustrated in FIG. 6, thesecond layer 38 can be bonded in the central region of the first length44 of the first layer 36. The central region of the first length 44 canbe the area adjacent a center line 84 of the first length 44 of thefirst layer 36 of the absorbent structure 34. It is to be understoodthat the central region of the first length 44 does not need to be theexact center of the first layer 36, but can be located generally aroundthe center line 84 of the first length 44. In an embodiment, the centralregion of the first layer 36 can be a position along the first length 44which can be a distance 86 that can be about 0.35 to about 0.65 timesthe first length 44, as measured from either transverse edge, 48 or 50,of the first layer 36. In an embodiment, the second layer 38 does nothave to be bonded to the first layer 36 in the central region of thefirst length 44, but rather could be bonded to the first layer 36 in anarea adjacent to one of the transverse edges, 48 or 50, or at any otherposition along the first length 44 of the first layer 36 as deemedsuitable.

FIG. 7 provides an illustration of a non-limiting example of anembodiment of an absorbent structure 34 in which the first layer 36 isillustrated as having a first length 44 and a first width 46 that areeach greater than the second length 60 and the second width 62 of thesecond layer 38.

FIG. 8 provides an illustration of a non-limiting example of anabsorbent structure 34 in which less than 100% of surface 74 of secondlayer 38 can be in a face to face relationship with surface 56 of firstlayer 36. First width 46 can be substantially similar to second width62, however it should be realized that first width 46 can be greaterthan or less than second width 62. First length 44 can be greater than,less than, or substantially similar to second length 60.

In an embodiment in which a layer, such as layer 36 or 38, has a lengthand/or width smaller than a length and/or width of another layer, suchas layer 36 or 38, the layer with the smaller dimension can be bonded tothe layer with the larger dimension in any location as deemed suitable.

FIGS. 4-8 provide non-limiting illustrations in which the second layer38 can be positioned on top of the first layer 36. In an embodiment, thefirst layer 36 can be positioned on top of the second layer 38. In anembodiment, at least a portion of a layer, such as layer 36 or 38, canbe inset into another layer, such as layer 36 or 38. In an embodiment,all of a layer, such as layer 36 or 38, can be inset into another layer,such as layer 36 or 38. FIG. 9 provides a non-limiting example of anembodiment of an absorbent structure 34 in which at least a portion ofthe second layer 38 can be at least partially inset into the first layer36.

As described herein, each layer, such as layers 36 and 38, can havetransverse edges, such as transverse edges 48 and 50 of layer 36 andtransverse edges 64 and 66 of layer 38. In an embodiment, eachtransverse edge(s), 48, 50, 64 and/or 66, can be linear, non-linear,arcuate, and any combination thereof as deemed suitable. Such an edgecan be produced in any manner as deemed suitable, such as, but notlimited to, knife cutting, die cutting, or any other method known to oneskilled in the art. As described herein, a transverse edge can belocated at the insertion end 18, the withdrawal end 20 or a locationbetween the insertion and withdrawal ends, 18 and 20, of a resultanttampon 10.

In an embodiment, at least one layer, such as layer(s) 36 and/or 38, ofthe absorbent structure 34 can have at least one contact element 88.Without being bound by theory, it is believed that when the tampon 10 isin use the contact element 88 can at least partially expand outwardlyfrom the tampon 10 when contacted by bodily fluids. It is believed thatsuch expansion of the contact element 88 can reduce or prevent leakageof bodily fluids from the woman's vagina.

In an embodiment, a tampon 10 can have at least one contact element 88located at the insertion end 18 of the tampon 10. In an embodiment, atampon 10 can have at least one contact element 88 located at thewithdrawal end 20 of the tampon. In an embodiment, a tampon 10 can haveat least one contact element 88 located at both the insertion end 18 andthe withdrawal end 20 of the tampon 10. In an embodiment, a tampon 10can have at least one contact element 88 at a location of the tampon 10between the insertion end 18 and the withdrawal end 20. In anembodiment, a tampon 10 can have at least one contact element 88 at alocation of the tampon 10 between the insertion end 18 and thewithdrawal end 20 and at least one contact element 88 located at leastone of the insertion end 18 and/or the withdrawal end 20 of the tampon10.

In an embodiment, a contact element 88 can at least partially expandoutwardly from the tampon 10 when contacted by body fluids. Withoutbeing bound by theory, it is believed that, while the entire tampon 10may expand from a compressed configuration into a less compressedconfiguration when contacted by body fluids, when a contact element 88is contacted by body fluids and at least partially expands away from thetampon 10 as a result of such contact, the expansion of a contactelement 88 away from the tampon 10 can result in an expanded contactelement 88 region having a cross-sectional diameter that is greater thana cross-sectional diameter of the remaining expanded tampon 10. FIG. 1provides a non-limiting illustration of a compressed tampon 10 of thecurrent disclosure. As illustrated in FIG. 1, the tampon 10 can have atleast one contact element 88 located at the insertion end 18 of thetampon 10. FIG. 10 provides a non-limiting example of an activatedtampon 10, i.e., an expanded tampon 10, wherein the contact elements 88can expand away from the tampon 10 and the region of the contactelements 88 can have a greater cross-sectional diameter than theremainder of the tampon 10. As a contact element 88 expands outwardlyfrom the tampon 10, the contact element 88 can deform and follow thefolds and convolutions of the walls of the vaginal cavity in order torespond locally to the changes in the vaginal environment.

A contact element 88 can have a base 92. In an embodiment, a base 92 ofat least one contact element 88 can be located at the insertion end 18of a tampon 10. In an embodiment, a base 92 of at least one contactelement 88 can be located at the withdrawal end 20 of a tampon 10. In anembodiment, a base 92 of at least one contact element 88 can be locatedat the insertion end 18 of a tampon 10 and a base 92 of at least onecontact element 88 can be located at the withdrawal end 20 of a tampon10. In an embodiment, a base 92 of at least one contact element 88 canbe at a location between the insertion end 18 and the withdrawal end 20of a tampon 10. In an embodiment, a base 92 of at least one contactelement 88 can be at a location between the insertion end 18 and thewithdrawal end 20 of a tampon 10 and a base 92 of a contact element 88can be located at least one of the insertion end 18 and/or thewithdrawal end 20 of a tampon 10.

In an embodiment, a contact element 88 can be at least partially boundedby a free edge 94 and at least partially bounded by a base 92. In anembodiment, a portion of a free edge 94 of a contact element 88 can atleast partially align with the insertion end 18 of a tampon 10. In anembodiment, a portion of a free edge 94 of a contact element 88 can atleast partially align with the withdrawal end 20 of a tampon 10. In anembodiment, substantially all of the contact element 88 can be locatedbetween the insertion end 18 and the withdrawal end 20 of a tampon 10.In an embodiment, a portion of a free edge 94 of a contact element 88can be at least partially aligned with the insertion end 18 of a tampon10 and a portion of a free edge 94 of a contact element 88 can be atleast partially aligned with the withdrawal end 20 of a tampon 10. In anembodiment, substantially all of a contact element 88 can be locatedbetween the insertion end 18 and the withdrawal end 20 and a portion ofa free edge 94 of a contact element 88 can be at least partially alignedwith at least one of the insertion end 18 and/or the withdrawal end 20of a tampon 10.

In an embodiment, at least one contact element 88 can be orientedtowards the insertion end 18 of the tampon 10. In an embodiment, atleast one contact element 88 can be oriented towards the withdrawal end20 of the tampon 10. In an embodiment, at least one contact element 88can be oriented towards the insertion end 18 of the tampon 10 and atleast one contact element 88 can be oriented towards the withdrawal end20 of the tampon 10.

In an embodiment, each layer, such as layer 36 and 38, can have at leastone contact element 88 located at the insertion end 18, the withdrawalend 20, or at a location between the insertion end 18 and the withdrawalend 20 of a tampon 10. In such an embodiment, a contact element 88 of alayer, such as layer 36, can be, but does not have to be, located in thesame location (i.e., insertion end 18, withdrawal end 20, or a locationbetween the insertion end 18 and the withdrawal end 20) as a contactelement 88 of another layer, such as layer 38. In an embodiment, eachlayer, such as layer 36 and 38, can have at least one contact element 88located at the insertion end 18 of a tampon 10. In an embodiment, eachlayer, such as layer 36 and 38, can have at least one contact element 88located at the withdrawal end 20 of a tampon 10. In an embodiment, oneof the layers, such as layer 36 or 38, can have at least one contactelement 88 located at the insertion end 18 of a tampon 10 and anotherlayer, such as layer 36 or 38, can have at least one contact element 88located at the withdrawal end 20 of the tampon 10. In an embodiment,each of the layers, such as layers 36 and 38, can each have at least onecontact element 88 located at each of the insertion end 18 and thewithdrawal end 20 of a tampon 10. In an embodiment, one of the layers,such as layer 36 or 38, can have a contact element 88 located at leastone of the insertion end 18 and/or the withdrawal end 20 and anotherlayer, such as layer 36 or 38, can have a contact element 88 located ata location between the insertion end 18 and the withdrawal end 20 of atampon 10.

In an embodiment in which each of the layers, such as layers 36 and 38,have at least one contact element 88, the at least one contact element88 of each layer, such as layers 36 and 38, can be in any overlappingrelationship to each other as desired. In an embodiment, a contactelement 88 of layer 36 can substantially overlap a contact element 88 oflayer 38. In an embodiment, a contact element 88 of layer 36 canpartially overlap a contact element 88 of layer 38. In an embodiment, acontact element 88 of layer 36 can have minimal or no overlap with acontact element 88 of layer 38.

In an embodiment, at least one of the layer(s), such as layer(s) 36and/or 38, can have at least one contact element 88. In an embodiment,at least one of the layer(s), such as layer(s) 36 and/or 38, can have atleast 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 contact elements 88. In anembodiment, at least one of the layer(s), such as layer(s) 36 and/or 38,can have from 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 to 11, 12, 13, 14, 15,16, 17, 18, 19, or 20 contact elements 88. In an embodiment, each of thelayers, such as layers 36 and 38, can each have at least one contactelement 88. In an embodiment, each of the layers, such as layers 36 and38, can have at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 contact elements88. In an embodiment, each of the layers, such as layers 36 and 38, canhave from 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 to 11, 12, 13, 14, 15, 16,17, 18, 19, or 20 contact elements 88.

In an embodiment, at least one layer(s), such as layer(s) 36 and/or 38,can have at least one contact element 88 at least partially separatedfrom another contact element 88. In an embodiment, the partialseparation of one contact element 88 from another contact element 88 canoccur via an amplitude of an arc, a slit, or combination thereof.

FIGS. 11-24 illustrate various non-limiting examples of embodiments ofan absorbent structure 34 in which at least one layer, such as layer 36and/or 38, can have at least one contact element 88. It is to beunderstood that the configurations of absorbent structures 34 andcontact elements 88 described and illustrated herein are non-limitingand additional configurations are contemplated by this disclosure.

In an embodiment, a layer(s), such as layer 36 and/or 38, of anabsorbent structure 34 can have a transverse edge which can have anundulating arcuate pattern. In such an embodiment, the undulatingarcuate pattern can produce at least one contact element 88. Theamplitude of each arc can be any amplitude as deemed suitable. In suchan embodiment, a contact element 88 can be at least partially separatedfrom another contact element 88 by the amplitude of the arc. FIG. 11illustrates a non-limiting example of an absorbent structure 34 whichcan have two layers, 36 and 38. As illustrated in FIG. 11, layer 36 canhave a first width 46 which can be substantially the same as the secondwidth 62 of layer 38. As illustrated in FIG. 11, layer 36 can have afirst length 44 which can be longer than a second length 60 of layer 38.Layer 36 can have two transverse edges, 48 and 50, in which transverseedge 48 can have an undulating arcuate pattern. Such an undulatingarcuate pattern can produce contact elements 88 which can be at leastpartially separated from each other by the amplitude of an arc betweeneach contact element 88. In an embodiment, a transverse edge having anarcuate pattern can be located at the insertion end 18 of a resultanttampon 10. In an embodiment, a transverse edge having an arcuate patterncan be located at the withdrawal end 20 of a resultant tampon 10. In anembodiment, a transverse edge having an arcuate pattern can be locatedat a location between the insertion end 18 and the withdrawal end 20 ofa resultant tampon 10. In an embodiment, transverse edges having anarcuate pattern can be located at both the insertion end 18 and thewithdrawal end 20 of a resultant tampon 10. In an embodiment, alayer(s), 36 and/or 38, can have a transverse edge having an arcuatepattern at a location between the insertion end 18 and the withdrawalend 20 and a layer(s), 36 and/or 38, can have a transverse edge havingan arcuate pattern at least one of the insertion end 18 and/or thewithdrawal end 20 of the tampon 10.

In an embodiment, the free edge 94 of a contact element 88 can begenerated via a slit 96. A slit 96 can extend through a layer(s), suchas layer(s) 36 and/or 38, from a first surface and through to a secondsurface of the layer(s), such as layer(s) 36 and/or 38. For example, aslit 96 can be incorporated into layer 36, extending from a firstsurface 56 of layer 36 through to a second surface 58 of layer 36 toform a free edge 94 of a contact element 88. In an embodiment, alayer(s), such as layer(s) 36 and/or 38, can have at least one slit 96.In an embodiment, a layer(s), such as layer(s) 36 and/or 38, can have atleast 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 slits 96. In an embodiment, alayer(s), such as layer(s) 36 and/or 38, can have from about 1, 2, 3, 4,5, 6, 7, 8, 9, or 10 to about 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20slits 96. In an embodiment, a layer(s), such as layer(s) 36 and/or 38,can have the appropriate number of slits 96 to provide the desirednumber of contact elements 88.

In an embodiment, a slit 96 can be linear, arcuate, any other shape, orcombination thereof. In an embodiment, a slit 96 can have any length 98as desired. The length 98 can be measured as the distance between theterminal ends of the slit 96. In an embodiment in which the slit 96contains an arc, the arc length can be determined by any manner deemedsuitable by one of ordinary skill in order to determine the length 98 ofthe slit 96. In an embodiment, the length 98 of a slit 96 can range fromabout 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 or 15 mm to about16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29 or 30 mm. In anembodiment, the length 98 of a slit 96 can be greater than about 1, 2,3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 or 15 mm. In an embodiment, thelength 98 of a slit 96 can be less than about 30, 29, 28, 27, 26, 25,24, 23, 22, 21, 20, 19, 18, 17, 16, or 15 mm.

In an embodiment in which a layer, such as layer 36 or 38, has more thanone slit 96, each slit 96 can have the same length 98. In an embodimentin which a layer, such as layer 36 or 38, has more than one slit 96, aslit 96 can have a length 98 that differs from the length 98 of at leastone other slit 96. In an embodiment, at least about 20, 25, 40, 45, 50,55, 70, 75, 80 or 85% of the slits 96 in a layer, such as layer 36 or38, can have substantially the same length 98. In an embodiment, about25, 50, or 75% of the slits in a layer, such as layer 36 or 38, can havesubstantially the same length, such as a first slit length, and about25, 50, or 75% of the slits in the same layer, such as layer 36 or 38,can have substantially the same length, such as a second slit length,and the second slit length can be different from the first slit length.In an embodiment in which the slits 96 incorporated into a layer, suchas layer 36 or 38, have varying slit lengths, the slits 96 can beincorporated into the layer, such as layer 36 or 38, in any pattern ofslit lengths as desired.

In an embodiment, an absorbent structure 34 can have two layers, such aslayers 36 and 38, in which each layer, such as layers 36 and 38, canhave more than one slit 96. In an embodiment, each slit 96 in theabsorbent structure 34 can have the same length 98. In an embodiment,the absorbent structure 34 can have a slit 96 that can have a length 98that differs from the length 98 of at least one other slit 96 locatedwithin the absorbent structure 34. In an embodiment, at least about 20,25, 40, 45, 50, 55, 70, 75, 80 or 85% of the slits 96 in the absorbentstructure 34 can have substantially the same length 98. In anembodiment, about 25, 50, or 75% of the slits 96 in the absorbentstructure 34 can have substantially the same length, such as a firstslit length, and about 25, 50, or 75% of the slits 96 in the absorbentstructure 34 can have substantially the same length, such as a secondslit length, and the second slit length can be different from the firstslit length. In an embodiment in which the slits 96 incorporated intothe absorbent structure 34 have varying slit lengths, the slits 96 canbe incorporated into the absorbent structure 34 in any pattern of slitlengths as desired.

In an embodiment, a slit 96 can be incorporated into at least onelayer(s), such as layer(s) 36 and/or 38, when the layer(s), such aslayer(s) 36 and/or 38, is in a flat, unfolded configuration or when thelayer(s), such as layer(s) 36 and/or 38, has a folded configuration. Inan embodiment, a slit 96 can be a continuous or intermittent cut. In anembodiment, a slit 96 can be a line of weakness.

In an embodiment, a slit 96 can be incorporated into a layer(s), such aslayer(s) 36 and/or 38, in any location of the layer(s), such as layer(s)36 and/or 38, as deemed suitable. For example, a slit 96 can beincorporated into a layer(s), such as layer(s) 36 and/or 38, between thetransverse edges of the layer(s), such as layer(s) 36 and/or 38, inassociation with a transverse edge of the layer(s), such as layer(s) 36and/or 38, and combinations thereof.

In an embodiment, a slit 96 can be incorporated into at least onelayer(s), such as layer(s) 36 and/or 38, and can be located in anydesired location between the transverse edges of the layer(s), such aslayer(s) 36 and/or 38. In such an embodiment, the slit 96 need not beassociated with transverse edges of the layer(s), such as layer(s) 36and/or 38. In such an embodiment, the slit 96 can be linear, arcuate,any other shape as desired, or combination thereof and can have anylength 98 as desired. In such an embodiment, more than one slit 96 canbe incorporated into the at least one layer(s), such as layer(s) 36and/or 38, and each slit 96 can be separated from any other slit 96 byany distance as deemed suitable. In such an embodiment, the slit 96 cancreate a contact element 88 that can be at least partially bounded by afree edge 94 and at least partially bounded by a base 92.

FIG. 12 provides a non-limiting example of an absorbent structure 34which can have two layers, 36 and 38. The first layer 36 of theabsorbent structure 34 can have a first length 44 which can be greaterthan the second length 60 of the second layer 38. The first width 46 ofthe first layer 36 can be substantially similar to the second width 62of the second layer 38. The first layer 36 can have two transverseedges, 48 and 50, and the second layer 38 can have two transverse edges,64 and 66. In the non-limiting example, transverse edge 66 of the secondlayer 38 can be substantially aligned with transverse edge 50 of thefirst layer 36. In the non-limiting illustration of FIG. 12, first layer36 can have at least one slit 96 located between transverse edges 48 and50 of layer 36. The slits 96 can extend from a first surface 56 of thefirst layer 36 through to a second surface 58 of the first layer 36. Theslits 96 can be in any configuration as desired, such as, for example,an arcuate configuration. It should be realized that the slits 96 canhave any length 98 as desired and can be spaced apart from each otherany distance as desired. As described herein, transverse edge 48 can belocated at the insertion end 18 or the withdrawal end 20 of a resultanttampon 10. In an embodiment, the contact elements 88 of the absorbentstructure 34 illustrated in FIG. 12 can be located at the insertion end18 or the withdrawal end 20 of a resultant tampon 10. In thenon-limiting embodiment illustrated in FIG. 12, the contact elements 88can be oriented towards the insertion end 18 or the withdrawal end 20 ofa resultant tampon 10. In an embodiment, a slit 96 can also beincorporated into second layer 38.

In an embodiment, a slit 96 can be associated with a transverse edge ofa layer, such as, for example, transverse edge 48 of layer 36, and canextend from the transverse edge 48 in a direction towards the interiorregion of the layer, such as, for example, the interior region of layer36. In such an embodiment, the slit 96 can extend from the transverseedge 48 of layer 36 in a direction towards the opposite transverse edge,edge 50, of layer 36. As described herein, in an embodiment, a slit 96need not be associated with a transverse edge of a layer, such astransverse edge 48 of layer 36.

In an embodiment, such as, for example, an embodiment in which more thanone slit 96 can be associated with a transverse edge of a layer, such aslayer 36 or 38, a width 102 (illustrated in FIG. 13) can separate a slit96 from the next successive slit 96. The width 102 can be any distanceas deemed suitable. In an embodiment, the width 102 can range from about1, 2, 3, 4, 5, 6 or 7 mm to about 8, 9, 10, 11, 12, 13, 14 or 15 mm. Inan embodiment in which slits 96 are associated with a transverse edge ofa layer, such as layer 36 or 38, as described herein, the width 102 canbe the width of a contact element 88. Two successive slits 96 associatedwith a transverse edge can create a contact element 88.

FIG. 13-24 illustrate various embodiments of slits 96 incorporated intoat least one layer, 36 and/or 38, of an absorbent structure 34 andassociated with a transverse edge. As shown in the non-limiting examplesof FIG. 13-24, the slits 96 can be incorporated into a layer(s), 36and/or 38, such as, for example, by being cut through from a firstsurface to a second surface of at least one layer, such as layer 36and/or 38. While particular embodiments are illustrated and described,it is to be understood that various changes and modifications can bemade to the embodiments illustrated and described without departing fromthe spirit and scope of the disclosure.

FIG. 13 provides a non-limiting example of an absorbent structure 34which can have two layers, 36 and 38. The first layer 36 of theabsorbent structure 34 can have a first length 44 which can be greaterthan the second length 60 of the second layer 38. The first width 46 ofthe first layer 36 can be substantially similar to the second width 62of the second layer 38. The first layer 36 can have two transverseedges, 48 and 50, and the second layer 38 can have two transverse edges,64 and 66. In the non-limiting example, transverse edge 66 of the secondlayer 38 can be substantially aligned with transverse edge 50 of thefirst layer 36. In the non-limiting illustration of FIG. 13, first layer36 can have at least one slit 96 associated with transverse edge 48. Thefirst layer 36 can have at least two successive slits 96 associated withtransverse edge 48 and the two successive slits 96 can create a contactelement 88. The slits 96 can extend from a first surface 56 of the firstlayer 36 through to a second surface 58 of the first layer 36. The slits96 can extend from the transverse edge 48 in a direction away from thetransverse edge 48 and towards an interior region of the first layer 36of the absorbent structure 34 such that the slits 96 can extend in adirection toward the opposite transverse edge 50 of the first layer 36.It should be realized that the slits 96 can have any length 98 asdesired as the slits 96 extend from transverse edge 48 in a directiontowards the opposite transverse edge 50 of the first layer 36. Asillustrated in FIG. 13 in a non-limiting embodiment, at least one of theslits 96 can have a first slit length 104 and at least one of the slits96 can have a second slit length 106 wherein the first slit length 104and the second slit length 106 are not the same. As illustrated in FIG.13 in the non-limiting embodiment illustrated, the slits 96 may beincorporated into layer 36 in a pattern of alternating lengths. In anembodiment in which slits 96 having different lengths are incorporatedinto a layer, such as layer 36 and/or 38, the slits 96 having differentlengths can be incorporated into the respective layer such that thedifferent lengths of the slits 96 can be in a random sequence, in analternating pattern, or in a repeating pattern. As illustrated in FIG.13, the slits 96 do not necessarily extend the entire first length 44 ofthe first layer 36. While the second layer 38 is illustrated such thattransverse edge 66 can be substantially aligned with transverse edge 50of the first layer 36, it should be realized that transverse edge 66 ofsecond layer 38 does not need to be substantially aligned withtransverse edge 50 of the first layer 36. It should be realized thatsecond layer 38 can be bonded to the first layer 36 at any positionalong the first length 44 of the first layer 36 as deemed suitable. Itshould be realized that transverse edge 64 of second layer 38 can alsobe positioned anywhere along the first length 44 of the first layer 36as desired and the second length 60 of second layer 38 can be anydimension as desired. In an embodiment, layer 38 can at least partiallyor completely overlay the contact elements 88 incorporated into layer36. As described herein, transverse edge 48 can be located at theinsertion end 18 or the withdrawal end 20 of a resultant tampon 10. Inan embodiment, the contact elements 88 of the absorbent structure 34illustrated in FIG. 13 can be located at the insertion end 18 or thewithdrawal end 20 of a resultant tampon 10. In the non-limitingembodiment illustrated in FIG. 13, the contact elements 88 can beoriented towards the insertion end 18 or the withdrawal end 20 of aresultant tampon 10. In an embodiment, a slit 96 can also beincorporated into second layer 38.

FIG. 14 provides an illustration of a non-limiting example of anembodiment of an absorbent structure 34 in which the first layer 36 canhave a first length 44 greater than the second length 60 of the secondlayer 38. As illustrated in FIG. 14, the first width 46 of the firstlayer 36 can be substantially similar to the second width 62 of thesecond layer 38. In the non-limiting example illustrated in FIG. 14, thesecond layer 38 can be bonded to the first layer 36 in the centralregion of the first length 44 of the first layer 36. The central regionof the first length 44 can be the area adjacent a center line 84 of thefirst length 44 of the first layer 36 of the absorbent structure 34. Itis to be understood that the central region of the first length 44 doesnot need to be the exact center of the first layer 36, but can belocated generally around the center line 84 of the first length 44. Inan embodiment, the central region of the first layer 36 can be aposition along the first length 44 which can be a distance 86 that canbe about 0.35 to about 0.65 times the first length 44, as measured fromeither transverse edge, 48 or 50, of the first layer 36. In anembodiment, the second layer 38 does not have to be bonded to the firstlayer 36 in the central region of the first length 44, but rather couldbe bonded to the first layer 36 in an area adjacent to one of thetransverse edges, 48 or 50, or at any other position along the firstlength 44 of the first layer 36 as deemed suitable. In the non-limitingillustration of FIG. 14, the first layer 36 can have at least one slit96 associated with each of the transverse edges, 48 and 50, of firstlayer 36. The first layer 36 can have at least two successive slits 96associated with transverse edges 48 and 50, respectively, and the twosuccessive slits 96 associated with a transverse edge can create acontact element 88. The slits 96 can extend from a first surface 56 ofthe first layer 36 through to a second surface 58 of the first layer 36.The slits 96 can extend from the transverse edge, 48 or 50,respectively, in a direction towards an interior region of the firstlayer 36 of the absorbent structure 34 such that the slits 96 can extendfrom the associated transverse edge, 48 or 50, and in a direction towardthe opposite transverse edge, 48 or 50, respectively, of the first layer36. It should be realized that the slits 96 can have any length 98 asdesired as the slits 96 extend from a transverse edge, 48 or 50, in adirection towards the opposite transverse edge, 48 or 50, of the firstlayer 36. As illustrated in FIG. 14 in a non-limiting embodiment, atleast one of the slits 96 can have a first slit length 104 and at leastone of the slits 96 can have a second slit length 106 wherein the firstslit length 104 and the second slit length 106 are not the same. Asillustrated in FIG. 14 in a non-limiting embodiment, the slits 96 may beincorporated into layer 36 in a pattern of alternating lengths. In anembodiment in which slits 96 having different lengths are incorporatedinto a layer, such as layer 36 and/or 38, the slits 96 having differentlengths can be incorporated into the respective layer such that thedifferent lengths of the slits 96 can be in a random sequence, in analternating pattern, or in a repeating pattern. As illustrated in FIG.14, the slits 96 do not necessarily extend the entire first length 44 ofthe first layer 36. It should be realized that transverse edges, 64 and66, of second layer 38 can be positioned anywhere along the first length44 of the first layer 36 as desired and the second length 60 of secondlayer 38 can be any dimension as desired. In an embodiment, layer 38 canat least partially or completely overlay the contact elements 88incorporated into layer 36. As described herein, the transverse edges,48 and 50, can be located at the insertion end 18 and the withdrawal end20 of a resultant tampon 10. Thus, in an embodiment, the contactelements 88 of the absorbent structure 34 illustrated in FIG. 14 can belocated at the insertion end 18 and the withdrawal end 20 of a resultanttampon 10. In the non-limiting embodiment illustrated in FIG. 14, thecontact elements 88 can be oriented towards the insertion end 18 and thewithdrawal end 20 of a resultant tampon 10. In an embodiment, a slit 96can also be incorporated into second layer 38.

FIG. 15 provides an illustration of a non-limiting example of anembodiment of an absorbent structure 34 in which the first layer 36 canhave a first width 46 greater than the second width 62 of the secondlayer 38. As illustrated in FIG. 15, the first length 44 of the firstlayer 36 can be substantially similar to the second length 60 of thesecond layer 38. In the non-limiting example illustrated in FIG. 15, thesecond layer 38 can be bonded to the central region of the first width46 of the first layer 36. The central region of the first width 46 canbe the area adjacent a center line 78 of the first width 46 of the firstlayer 36 of the absorbent structure 34. It is to be understood that thecentral region of the first width 46 does not need to be the exactcenter of the first layer 36, but can be located generally around thecenter line 78 of the first width 46. In an embodiment, the centralregion of the first width 46 of the first layer 36 can be a positionalong the first width 46 which can be a distance 80 that can be about0.35 to about 0.65 times the first width 46, as measured from eitherlongitudinal edge, 52 or 54, of the first layer 36. In an embodiment,the second layer 38 does not have to be bonded to the first layer 36 inthe central region of the first width 46, but rather could be bonded tothe first layer 36 in an area adjacent to one of the longitudinal edges,52 or 54, or at any other position along the first width 46 of the firstlayer 36 as deemed suitable. In the non-limiting embodiment of FIG. 15,first layer 36 can have at least one slit 96 associated with transverseedge 48 and second layer 38 can have at least one slit 96 associatedwith transverse edge 64. Each layer, 36 and 38, can have at least twosuccessive slits 96 associated with their respective transverse edges,48 and 64, and the two successive slits 96 can create a contact element88 in each layer, 36 and 38. With regards to the at least one slit 96associated with the transverse edge 48 of the first layer 36, the slit96 can extend from a first surface 56 of the first layer 36 through to asecond surface 58 of the first layer 36. The slit 96 associated withtransverse edge 48 can extend from the transverse edge 48 in a directiontowards an interior region of the first layer 36 of the absorbentstructure 34 such that the slit 96 can extend in a direction towards theopposite transverse edge 50 of the first layer 36. With regards to theat least one slit 96 associated with the transverse edge 64 of thesecond layer 38, the slit 96 can extend from a first surface 72 throughto a second surface 74 of the second layer 38. The slit 96 associatedwith transverse edge 64 can extend from the transverse edge 64 in adirection towards an interior region of the second layer 38 of theabsorbent structure 34 such that the slit 96 can extend from thetransverse edge 64 in a direction towards the opposite transverse edge66 of the second layer 38. While the slits 96 of the first layer 36 andthe slits 96 of the second layer 38 are illustrated in a manner in whichthe slits 96 of the second layer 38 can be positioned to substantiallyalign with the slits 96 of the first layer 36, it should be realizedthat the slits 96 of the second layer 38 can be offset from the slits 96of the first layer 36. An offset of the slits 96 of the second layer 38from the slits 96 of the first layer 36 can be in any amount as deemedsuitable. It should be realized that the slits 96 of each of the layers,36 and 38, can have any length 98 as desired as the slits 96 extend froma transverse edge, 48 or 64, in a direction towards the oppositetransverse edge, 50 or 66, of the first layer 36 or second layer 38,respectively. As illustrated in FIG. 15 in a non-limiting embodiment, atleast one of the slits 96 of layer 36 and/or 38 can have a first slitlength 104 and at least one of the slits 96 of the same layer, 36 and/or38, can have a second slit length 106 wherein the first slit length 104and the second slit length 106 are not the same. As illustrated in FIG.15 in a non-limiting embodiment, the slits 96 may be incorporated intolayer 36 and layer 38 in a pattern of alternating lengths. In anembodiment in which slits 96 having different lengths are incorporatedinto a layer, such as layer 36 and/or 38, the slits 96 having differentlengths can be incorporated into the respective layer such that thedifferent lengths of the slits 96 can be in a random sequence, in analternating pattern, or in a repeating pattern. As illustrated in FIG.15, the slits 96 do not necessarily extend the entire length, 44 or 60,of the first layer 36 or the second layer 38, respectively. As describedherein, the transverse edges, 48, 50, 64, and 66, can be located at theinsertion end 18 or the withdrawal end 20 of a resultant tampon 10.Thus, in an embodiment, the contact elements 88 of the absorbentstructure 34 illustrated in FIG. 15 can be located at the insertion end18 or the withdrawal end 20 of a resultant tampon 10. In thenon-limiting embodiment illustrated in FIG. 15, the contact elements 88of layers 36 and 38 can be oriented towards the insertion end 18 or thewithdrawal end 20 of a resultant tampon 10. In an embodiment, at leastone of the layers, 36 and/or 38, can also have at least one slit 96associated with the opposite transverse edge, 50 and/or 66,respectively. It should be realized that in the non-limiting embodimentillustrated in FIG. 15, the contact elements 88 of the first layer 36and the contact elements 88 of the second layer 38 need not be bonded toeach other. Thus, it should be realized that the two layers, 36 and 38,do not need to be bonded to each other in any region wherein a contactelement 88 is present.

FIG. 16 provides an illustration of a non-limiting example of anembodiment of an absorbent structure 34 in which the first layer 36 canhave a first length 44 and a first width 46 that can each be greaterthan the second length 60 and the second width 62 of the second layer38. In the non-limiting illustration of FIG. 16, first layer 36 can haveat least one slit 96 associated with a transverse edge such astransverse edge 48. The first layer 36 can have at least two successiveslits 96 associated with transverse edge 48 and the two successive slits96 can create a contact element 88. The slits 96 can extend from a firstsurface 56 of the first layer 36 through to a second surface 58 of thefirst layer 36. The slits 96 can extend from the transverse edge 48 in adirection away from the transverse edge 48 and towards an interiorregion of the first layer 36 of the absorbent structure 34 such that theslits 96 can extend in a direction toward the opposite transverse edge50 of the first layer 36. It should be realized that the slits 96 canhave any length 98 as desired as the slits 96 extend from transverseedge 48 in a direction towards the opposite transverse edge 50 of thefirst layer 36. As illustrated in FIG. 16 in a non-limiting embodiment,each slit 96 can have a length 98 substantially similar to the length 98of each other slit 96 present. In an embodiment, the slits 96 can havevarying lengths 98. As illustrated in FIG. 16, the slits 96 do notnecessarily extend the entire first length 44 of the first layer 36. Inan embodiment, the slits 96 can extend a length 98 that is substantiallysimilar to, less than or greater than a distance 118 between transverseedge 48 and transverse edge 64. It should be realized that second layer38 can be bonded to the first layer 36 at any position along the firstlength 44 and/or first width 46 of the first layer 36 as deemed suitableand can have any size dimension as deemed suitable. It should berealized that the two layers, 36 and 38, do not need to be bonded toeach other in any region wherein a contact element 88 is present. Asdescribed herein, the transverse edge 48 can be located at the insertionend 18 or the withdrawal end 20 of a resultant tampon 10. Thus, in anembodiment, the contact elements 88 of the absorbent structure 34illustrated in FIG. 16 can be located at the insertion end 18 or thewithdrawal end 20 of a resultant tampon 10. In the non-limitingembodiment illustrated in FIG. 16, the contact elements 88 can beoriented towards the insertion end 18 or the withdrawal end 20 of aresultant tampon 10. In embodiment, at least one slit 96 can also beincorporated into second layer 38.

FIG. 17 provides an illustration of a non-limiting example of anembodiment of an absorbent structure 34 which can have two layers, 36and 38. As illustrated, first layer 36 can have a first width 46 thatcan be substantially similar to a second width 62 of the second layer38. As illustrated, first layer 36 can have at least one fold 110incorporated therein. In such an embodiment in which a fold 110 ispresent, the first layer 36 can be bent upon itself such that a firstportion of at least one of the surfaces, 56 or 58, can be incommunication with a second portion of the same surface, 56 or 58. As anon-limiting example, as illustrated in FIG. 17, the first layer 36 cancontain a single fold 110 bringing a first portion 112 of the firstsurface 56 into communication with a second portion 114 of the firstsurface 56. In the non-limiting embodiment illustrated in FIG. 17, thefold 110 can bring transverse edge 48 of first layer 36 intocommunication with transverse edge 64 of the second layer 38. It shouldbe realized that layer 36 can have a first length 44 greater than asecond length 60 of layer 38 and fold 110 can occur at any desiredlocation along the first length 44 of layer 36. In an embodiment, a fold110 can bring transverse edge 48 of layer 36 into communication withtransverse edge 64 of layer 38, into communication with a portion ofsecond layer 38 located between transverse edges 64 and 66, intocommunication with transverse edge 66 of second layer 38, into aconfiguration wherein transverse edge 48 can extend beyond transverseedge 66, or to a location of first layer 36 such that transverse edge 48is not in communication with the second layer 38. As illustrated, firstlayer 36 can have at least one slit 96 which can be cut through from asecond surface 58, through the first and second portions, 112 and 114,of the first surface 56, and to the opposite second surface 58 of thefirst layer 36. The first layer 36 can have at least two successiveslits 96 and the two successive slits 96 can create a contact element88. As illustrated, the slit(s) 96 can be associated with the fold 110of the first layer 36. The slit(s) 96 can extend from the fold 110 ofthe first layer 36 in a direction away from the fold 110 and towards theinterior region of the absorbent structure 34 such that the slits 96 canextend from the fold 110 of first layer 36 in a direction towardstransverse edge 50 of layer 36. The slit(s) 96 can be incorporated intothe first layer 36 prior to or after fold 110 has been incorporated intolayer 36. It should be realized that, in an embodiment, at least oneslit 96 can be incorporated into second layer 38. In an embodiment, atleast one of the layers, 36 and/or 38, can have at least one slit 96associated with the transverse edges, 48, 50, 64 and/or 66,respectively. As described herein, the fold 110 can be located at theinsertion end 18 or the withdrawal end 20 of a resultant tampon 10.Thus, in an embodiment, the contact elements 88 of the absorbentstructure 34 illustrated in FIG. 17 can be located at the insertion end18 or the withdrawal end 20 of a resultant tampon 10. In thenon-limiting embodiment illustrated in FIG. 17, the contact elements 88can be oriented towards the insertion end 18 or the withdrawal end 20 ofa resultant tampon 10.

FIG. 18 provides an illustration of a non-limiting example of anembodiment of an absorbent structure 34 which can have two layers 36 and38. As illustrated, the first layer 36 can have two transverse edges, 48and 50, and the second layer 38 can have two transverse edges, 64 and66. In an embodiment, the first layer 36 can have more than one fold,such as folds 110 and 122, incorporated therein. In such an embodiment,the first fold 110 can bring transverse edge 48 of first layer 36 intocommunication with transverse edge 64 of the second layer 38. In anembodiment, fold 110 can bring transverse edge 48 of layer 36 intocommunication with transverse edge 64 of layer 38, into communicationwith a portion of layer 38 located between transverse edges 64 and 66,into communication with transverse edge 66 of layer 38, into aconfiguration wherein transverse edge 48 can extend beyond transverseedge 66, or to a location of layer 36 such that transverse edge 48 isnot in communication with layer 38. In such an embodiment, a firstportion 112 of first surface 56 of the first layer 36 can be broughtinto a face-to-face relationship with a second portion 114 of firstsurface 56 of the first layer 36. In an embodiment, the fold 110 can beutilized to bring the two portions, 112 and 114, into a facingrelationship and, in some embodiments, a space 120 can exist between thetwo portions, 112 and 114, while they are in a facing relationship. Inan embodiment, such as illustrated in the non-limiting embodiment ofFIG. 18, a second fold 122 can be incorporated into layer 36. In thenon-limiting illustration, the second fold 122 can be incorporated intolayer 36 at any location of the first layer 36 such as, for example, ata location between the transverse edge 48 and the first fold 110. Thesecond fold 122 can be configured such that the second fold 122 canposition a portion of the first layer 36 into the space 120 created bythe first fold 110. The second fold 122 can bring a first portion 124 ofthe second surface 58 into a facing relationship with a second portion126 of the second surface 58 of the first layer 36. The first layer 36can have at least one slit 96 incorporated therein (not shown). The atleast one slit 96 can be incorporated into layer 36 before or after theincorporation of either of the folds, 110 and/or 122. The at least oneslit 96 can be associated with either or both of the folds 110 and/or122. In an embodiment in which slits 96 are associated with only one ofthe folds, 110 or 122, the contact element(s) 88 formed by theincorporation of the slits 96 can be in an at least partiallyoverlapping relationship with a portion of the folded first layer 36 notcontaining any slits 96 or contact elements 88. In an embodiment inwhich slits 96 are associated with each of the folds, 110 and 122, thecontact element(s) 88 formed by the incorporation of the slits 96 can bein an at least partially overlapping relationship. As described herein,the folds 110 and 122 can be located at the insertion end 18 or thewithdrawal end 20 of a resultant tampon 10. Thus, in an embodiment, thecontact elements 88 of the absorbent structure 34 illustrated in FIG. 18can be located at the insertion end 18 or the withdrawal end 20 of aresultant tampon 10. In the non-limiting embodiment illustrated in FIG.18, the contact elements 88 can be oriented towards the insertion end 18or the withdrawal end 20 of a resultant tampon 10. In an embodiment, atleast one slit 96 can be incorporated into second layer 38. In anembodiment, at least one of the layers, 36 and/or 38, can have at leastone slit 96 associated with the transverse edges, 48, 50, 64 and/or 66,respectively.

FIG. 19 provides an illustration of a non-limiting embodiment of anabsorbent structure 34 which can have two layers, 36 and 38. Asillustrated, the first layer 36 can have a first width 46 that can besubstantially similar to a second width 62 of the second layer 38. Thefirst layer 36 can have a first length 44 which can be longer than asecond length 60 of the second layer 38. As illustrated, first layer 36can have at least two folds, 110 and 122, incorporated therein. In suchan embodiment in which two folds, 110 and 122, are present, the layer 36can be bent upon itself such that a first portion of one surface, 56 or58, of the layer 36 can be in a facing relationship with a secondportion of the same surface, 56 or 58, and a third portion of onesurface, 56 or 58, of the layer 36 can be in a facing relationship witha first portion of the other surface, 56 or 58. As a non-limitingexample, as illustrated in FIG. 19, the layer 36 can contain a firstfold 110 bringing a first portion 112 of the first surface 56 into afacing relationship with a second portion 114 of the first surface 56.Following the creation of the first fold 110, the transverse edge 48 oflayer 36 can be located at any location along the first length 44 oflayer 36 between the first fold 110 and transverse edge 64 of layer 38.The layer 36 can contain a second fold 122 bringing a third portion 128of the first surface 56 into a facing relationship with a first portion124 of the second surface 58 of layer 36. The second fold 122 can becreated by bending layer 36 at a location along the first length 44 oflayer 36 between the transverse edge 48 of layer 36 and the transverseedge 64 of layer 38. As illustrated in FIG. 19, following the folding oflayer 36 with fold 122, transverse edge 48 need not be in communicationwith second layer 38 of the absorbent structure 34. In an embodiment,each fold 110 and 122 can result in layer 36 having multiple layers,such as layers 130, 132, and 134. In an embodiment, layer 36 can have atleast one slit 96 extending through the layers, 130, 132 and 134, of thelayer 36. The first layer 36 can have at least two successive slits 96and the two successive slits 96 can create a contact element 88. Asillustrated, the at least one slit 96 can extend from the second surface58 of layer 36, through the first and second portions, 112 and 114, ofthe first surface 56 of layer 36, through the first portion 124 of thesecond surface 58 of layer 36 and the third portion 128 of the firstsurface 56 of layer 36, and to the opposite second surface 58 of thefirst layer 36. As illustrated, the slit(s) 96 can be associated withthe second fold 122 of the first layer 36. The slit(s) 96 can extendfrom the fold 122 of the first layer 36 in a direction away from thefold 122 and towards the interior region of the absorbent structure 34such that the slits 96 can extend from the fold 122 of first layer 36 ina direction towards transverse edge 50 of layer 36. The at least oneslit 96 can be incorporated into layer 36 prior to or after layer 36 hasbeen folded. As described herein, the fold 122 can be located at theinsertion end 18 or the withdrawal end 20 of a resultant tampon 10.Thus, in an embodiment, the contact elements 88 of the absorbentstructure 34 illustrated in FIG. 19 can be located at the insertion end18 or the withdrawal end 20 of a resultant tampon 10. In thenon-limiting embodiment illustrated in FIG. 19, the contact elements 88can be oriented towards the insertion end 18 or the withdrawal end 20 ofa resultant tampon 10. In an embodiment, at least one slit 96 can beincorporated into second layer 38. In an embodiment, at least one of thelayers, 36 and/or 38, can have at least one slit 96 associated with thetransverse edges, 48, 50, 64 and/or 66, respectively.

FIG. 20 provides an illustration of a non-limiting embodiment of anabsorbent structure 34 which can have two layers, 36 and 38. Asillustrated, the first layer 36 can have a first width 46 that can besubstantially similar to a second width 62 of the second layer 38. Thefirst layer 36 can have a first length 44 which can be longer than asecond length 60 of the second layer 38. As illustrated, first layer 36can have at least two folds, 110 and 122, incorporated therein. In suchan embodiment in which two folds, 110 and 122, are present, the layer 36can be bent upon itself such that a first portion of one surface, 56 or58, of the layer 36 can be in a facing relationship with a secondportion of the same surface, 56 or 58, and a third portion of onesurface, 56 or 58, of the layer 36 can be in a facing relationship witha first portion of the other surface, 56 or 58. As a non-limitingexample, as illustrated in FIG. 20, the layer 36 can contain a firstfold 110 bringing a first portion 112 of the first surface 56 into afacing relationship with a second portion 114 of the first surface 56.Following the creation of the first fold 110, the transverse edge 48 oflayer 36 can be located at any location along the first length 44 oflayer 36 between the first fold 110 and transverse edge 64 of layer 38.The layer 36 can contain a second fold 122 bringing a third portion 128of the first surface 56 into a facing relationship with a first portion124 of the second surface 58 of layer 36. The second fold 122 can becreated by bending layer 36 at a location along the first length 44 oflayer 36 between the transverse edge 48 of layer 36 and the transverseedge 64 of layer 38. As illustrated in FIG. 20, following the folding oflayer 36 with fold 122, transverse edge 48 need not be in communicationwith second layer 38 of the absorbent structure 34. In an embodiment,each fold 110 and 122 can result in layer 36 having multiple layers,such as layers 130, 132, and 134. In an embodiment, layer 36 can have atleast one slit 96 extending through the layers, 130 and 132, of thelayer 36. The first layer 36 can have at least two successive slits 96extending through the layers, 130 and 132, and the two successive slits96 can create a contact element 88. As illustrated, the at least oneslit 96 can extend from the second surface 58 of layer 36 and throughthe first and second portions, 112 and 114, of the first surface 56 oflayer 36 to the first portion 124 of the second surface 58 of layer 36.As illustrated, the slit(s) 96 can be associated with the first fold 110of the first layer 36. The slit(s) 96 can extend from the fold 110 ofthe first layer 36 in a direction away from the fold 110 and towards thesecond fold 122 of the first layer 36. The at least one slit 96 can beincorporated into layer 36 prior to or after layer 36 has been foldedwith the first fold 110. As described herein, the fold 110 can belocated at a location between the insertion end 18 and the withdrawalend 20 of a resultant tampon 10. Thus, in an embodiment, the contactelements 88 of the absorbent structure 34 illustrated in FIG. 20 can belocated at a location between the insertion end 18 and the withdrawalend 20 of a resultant tampon 10. In the non-limiting embodimentillustrated in FIG. 20, the contact elements 88 can be oriented towardsthe insertion end 18 or the withdrawal end 20 of a resultant tampon 10.In an embodiment, at least one slit 96 can be incorporated into secondlayer 38. In an embodiment, at least one of the layers, 36 and/or 38,can have at least one slit 96 associated with the transverse edges, 48,50, 64 and/or 66, respectively.

FIG. 21 provides an illustration of a non-limiting embodiment of anabsorbent structure 34 which can have two layers, 36 and 38. Asillustrated, the first layer 36 can have a first width 46 that can besubstantially similar to a second width 62 of the second layer 38. Thefirst layer 36 can have a first length 44 which can be longer than asecond length 60 of the second layer 38. As illustrated, less than 100%of surface 74 of second layer 38 can be in a face to face relationshipwith surface 56 of first layer 36. As illustrated, first layer 36 canhave at least two folds, 110 and 122, incorporated therein. In such anembodiment in which two folds 110 and 122 are present, the layer 36 canbe bent upon itself such that a first portion of one surface, 56 or 58,of the layer 36 can be in a facing relationship with a second portion ofthe same surface, 56 or 58, and a third portion of one surface, 56 or58, of the layer 36 can be in a facing relationship with a first portionof the other surface, 56 or 58. As a non-limiting example, asillustrated in FIG. 21, the layer 36 can contain a first fold 110bringing a first portion 112 of the first surface 56 into a facingrelationship with a second portion 114 of the first surface 56.Following the creation of the first fold 110, the transverse edge 48 oflayer 36 can be located at any location along the first length 44 oflayer 36 between the first fold 110 and transverse edge 64 of layer 38.The layer 36 can contain a second fold 122 bringing a third portion 128of the first surface 56 into a facing relationship with a first portion124 of the second surface 58 of layer 36. The second fold 122 can becreated by bending layer 36 at a location along the first length 44 oflayer 36 between the transverse edge 48 of layer 36 and the transverseedge 64 of layer 38. As illustrated in FIG. 21, following the folding oflayer 36 with fold 122, transverse edge 48 need not be in communicationwith second layer 38 of the absorbent structure 34. In an embodiment,each fold 110 and 122 can result in layer 36 having multiple layers,such as layers 130, 132, and 134. In an embodiment, layer 36 can have atleast one slit 96 extending through the layers, 130 and 132, of thelayer 36. The first layer 36 can have at least two successive slits 96extending through the layers, 130 and 132, and the two successive slits96 can create a contact element 88. As illustrated, the at least oneslit 96 can extend from the second surface 58 of layer 36 and throughthe first and second portions, 112 and 114, of the first surface 56 oflayer 36 to the first portion 124 of the second surface 58 of layer 36.As illustrated, the slit(s) 96 can be associated with the first fold 110of the first layer 36. The slit(s) 96 can extend from the fold 110 ofthe first layer 36 in a direction away from the fold 110 and towards thesecond fold 122 of the first layer 36. The at least one slit 96 can beincorporated into layer 36 prior to or after layer 36 has been foldedwith the first fold 110. As described herein, the fold 110 can belocated at a location between the insertion end 18 and the withdrawalend 20 of a resultant tampon 10. Thus, in an embodiment, the contactelements 88 of the absorbent structure 34 illustrated in FIG. 21 can belocated at a location between the insertion end 18 and the withdrawalend 20 of a resultant tampon 10. In the non-limiting embodimentillustrated in FIG. 21, the contact elements 88 can be oriented towardsthe insertion end 18 or the withdrawal end 20 of a resultant tampon 10.In an embodiment, at least one slit 96 can be incorporated into secondlayer 38. In an embodiment, at least one of the layers, 36 and/or 38,can have at least one slit 96 associated with the transverse edges, 48,50, 64 and/or 66, respectively.

FIG. 22 provides an illustration of a non-limiting embodiment of anabsorbent structure 34 which can have two layers, 36 and 38. Asillustrated, the first layer 36 can have a first width 46 that can besubstantially similar to a second width 62 of the second layer 38. Thefirst layer 36 can have a first length 44 which can be longer than asecond length 60 of the second layer 38. As illustrated, first layer 36can have at least two folds, 110 and 122, incorporated therein. In suchan embodiment as illustrated in FIG. 22 in which two folds, 110 and 122,are present, the layer 36 can be bent upon itself such that a firstportion of one surface, 56 or 58, of the layer 36 can be in a facingrelationship with a second portion of the same surface, 56 or 58, and afirst portion of the other surface, 56 or 58, of the layer 36 can be ina facing relationship with a second portion of the same surface, 56 or58. As a non-limiting example, as illustrated in FIG. 22, the layer 36can contain a first fold 110 bringing a first portion 112 of the firstsurface 56 into a facing relationship with a second portion 114 of thefirst surface 56. Following the creation of the first fold 110, thetransverse edge 48 of layer 36 can be located at any location along thefirst length 44 of layer 36 between the first fold 110 and transverseedge 64 of layer 38. The layer 36 can contain a second fold 122 bringinga first portion 124 of the second surface 58 into a facing relationshipwith a second portion 126 of the second surface 58 of layer 36. Thesecond fold 122 can be created by bending layer 36 at a location alongthe first length 44 of layer 36 between the transverse edge 48 of layer36 and the first fold 110 of layer 36. As illustrated in FIG. 22,transverse edge 48 of layer 36 can be in communication with transverseedge 64 of the second layer 38 of the absorbent structure 34. In anembodiment, each fold 110 and 122 can result in layer 36 having multiplelayers, such as layers 130, 132, 134 and 136. In an embodiment, layer 36can have at least one slit 96 extending through the layers, 130, 132,134 and 136, of the layer 36. The first layer 36 can have at least twosuccessive slits 96 extending through the layers, 130, 132, 134, and136, and the two successive slits 96 can create a contact element 88. Asillustrated, the at least one slit 96 can extend from the second surface58 of layer 36, through the first and second portions, 112 and 114, ofthe first surface 56 of layer 36, through the first and second portions,124 and 126, of the second surface 58 of layer 36, through oppositefirst and second portions, 112 and 114, of the first surface 56 of layer36, and to the opposite second surface 58 of the first layer 36. Asillustrated, the slit(s) 96 can be associated with the second fold 122of the first layer 36. The slit(s) 96 can extend from the fold 122 ofthe first layer 36 in a direction away from the fold 122 and towards theinterior region of the absorbent structure 34 such that the slits 96 canextend from the fold 122 of first layer 36 in a direction towardstransverse edge 50 of layer 36. The at least one slit 96 can beincorporated into layer 36 prior to or after layer 36 has been folded.As described herein, the fold 122 can be located at the insertion end 18or the withdrawal end 20 of a resultant tampon 10. Thus, in anembodiment, the contact elements 88 of the absorbent structure 34illustrated in FIG. 22 can be located at the insertion end 18 or thewithdrawal end 20 of a resultant tampon 10. In the non-limitingembodiment illustrated in FIG. 22, the contact elements 88 can beoriented towards the insertion end 18 or the withdrawal end 20 of aresultant tampon 10. In an embodiment, at least one slit 96 can beincorporated into second layer 38. In an embodiment, at least one of thelayers, 36 and/or 38, can have at least one slit 96 associated with thetransverse edges, 48, 50, 64 and/or 66, respectively.

FIG. 23 provides an illustration of a non-limiting embodiment of anabsorbent structure 34 which can have two layers, 36 and 38. Asillustrated, the first layer 36 can have a first width 46 that can besubstantially similar to a second width 62 of the second layer 38. Thefirst layer 36 can have a first length 44 which can be longer than asecond length 60 of the second layer 38. As illustrated, first layer 36can have at least two folds, 110 and 122, incorporated therein. In suchan embodiment as illustrated in FIG. 23 in which two folds, 110 and 122,are present, the layer 36 can be bent upon itself such that a firstportion of one surface, 56 or 58, of the layer 36 can be in a facingrelationship with a second portion of the same surface, 56 or 58, and afirst portion of the other surface, 56 or 58, of the layer 36 can be ina facing relationship with a second portion of the same surface, 56 or58. As a non-limiting example, as illustrated in FIG. 23, the layer 36can contain a first fold 110 bringing a first portion 112 of the firstsurface 56 into a facing relationship with a second portion 114 of thefirst surface 56. Following the creation of the first fold 110, thetransverse edge 48 of layer 36 can be located at any location along thefirst length 44 of layer 36 between the first fold 110 and transverseedge 64 of layer 38. The layer 36 can contain a second fold 122 bringinga first portion 124 of the second surface 58 into a facing relationshipwith a second portion 126 of the second surface 58 of layer 36. Thesecond fold 122 can be created by bending layer 36 at a location alongthe first length 44 of layer 36 between the transverse edge 48 of layer36 and the first fold 110 of layer 36. As illustrated in FIG. 23,transverse edge 48 of layer 36 can be in communication with transverseedge 64 of the second layer 38 of the absorbent structure 34. In anembodiment, each fold 110 and 122 can result in layer 36 having multiplelayers, such as layers 130, 132, 134 and 136. In an embodiment, layer 36can have at least one slit 96 extending through the layers, such aslayers 130 and 132, of the layer 36. The first layer 36 can have atleast two successive slits 96 extending through the layers, 130 and 132,and the two successive slits 96 can create a contact element 88. Asillustrated, the at least one slit 96 can extend from the second surface58 of layer 36, through the first and second portions, 112 and 114, ofthe first surface 56 of layer 36, and to the second portion 126 of thesecond surface 58 of layer 36. As illustrated, the slit(s) 96 can beassociated with the first fold 110 of the first layer 36. The slit(s) 96can extend from the fold 110 of the first layer 36 in a direction awayfrom the fold 110 and towards the second fold 122 of first layer 36. Theat least one slit 96 can be incorporated into layer 36 prior to or afterlayer 36 has been folded. As described herein, the fold 110 can belocated between the insertion end 18 and the withdrawal end 20 of aresultant tampon 10. Thus, in an embodiment, the contact elements 88 ofthe absorbent structure 34 illustrated in FIG. 23 can be located betweenthe insertion end 18 and the withdrawal end 20 of a resultant tampon 10.In the non-limiting embodiment illustrated in FIG. 23, the contactelements 88 can be oriented towards the insertion end 18 or thewithdrawal end 20 of a resultant tampon 10. In an embodiment, at leastone slit 96 can be incorporated into second layer 38. In an embodiment,at least one of the layers, 36 and/or 38, can have at least one slit 96associated with the transverse edges, 48, 50, 64 and/or 66,respectively.

FIG. 24 provides an illustration of a non-limiting embodiment of anabsorbent structure 34 which can have two layers, 36 and 38. Asillustrated, the first layer 36 can have a first width 46 that can besubstantially similar to a second width 62 of the second layer 38. Thefirst layer 36 can have a first length 44 which can be longer than asecond length 60 of the second layer 38. As illustrated, less than 100%of surface 74 of second layer 38 can be in a face to face relationshipwith surface 56 of first layer 36. As illustrated, first layer 36 canhave at least two folds, 110 and 122, incorporated therein. In such anembodiment as illustrated in FIG. 24 in which two folds 110 and 122 arepresent, the layer 36 can be bent upon itself such that a first portionof one surface, 56 or 58, of the layer 36 can be in a facingrelationship with a second portion of the same surface, 56 or 58, and afirst portion of the other surface, 56 or 58, of the layer 36 can be ina facing relationship with a second portion of the same surface, 56 or58. As a non-limiting example, as illustrated in FIG. 24, the layer 36can contain a first fold 110 bringing a first portion 112 of the firstsurface 56 into a facing relationship with a second portion 114 of thefirst surface 56. Following the creation of the first fold 110, thetransverse edge 48 of layer 36 can be located at any location along thefirst length 44 of layer 36 between the first fold 110 and transverseedge 64 of layer 38. The layer 36 can contain a second fold 122 bringinga first portion 124 of the second surface 58 into a facing relationshipwith a second portion 126 of the second surface 58 of layer 36. Thesecond fold 122 can be created by bending layer 36 at a location alongthe first length 44 of layer 36 between the transverse edge 48 of layer36 and the first fold 110 of layer 36. As illustrated in FIG. 24,transverse edge 48 of layer 36 does not have to be, but can be, incommunication with transverse edge 64 of the second layer 38 of theabsorbent structure 34. In an embodiment, each fold 110 and 122 canresult in layer 36 having multiple layers, such as layers 130, 132, 134and 136. In an embodiment, layer 36 can have at least one slit 96extending through the layers, 130 and 132, of the layer 36. The firstlayer 36 can have two successive slits 96 extending through the layers,130 and 132, and the two successive slits 96 can create a contactelement 88. As illustrated, the at least one slit 96 can extend from thesecond surface 58 of layer 36, through the first and second portions,112 and 114, of the first surface 56 of layer 36, and to the secondportion 126 of the second surface 58 of layer 36. As illustrated, theslit(s) 96 can be associated with the first fold 110 of the first layer36. The slit(s) 96 can extend from the fold 110 of the first layer 36 ina direction away from the fold 110 and towards the second fold 122 offirst layer 36. The at least one slit 96 can be incorporated into layer36 prior to or after layer 36 has been folded. As described herein, thefold 110 can be located between the insertion end 18 and the withdrawalend 20 of a resultant tampon 10. Thus, in an embodiment, the contactelements 88 of the absorbent structure 34 illustrated in FIG. 24 can belocated between the insertion end 18 and the withdrawal end 20 of aresultant tampon 10. In the non-limiting embodiment illustrated in FIG.24, the contact elements 88 can be oriented towards the insertion end 18or the withdrawal end 20 of a resultant tampon 10. In an embodiment, atleast one slit 96 can be incorporated into second layer 38. In anembodiment, at least one of the layers, 36 and/or 38, can have at leastone slit 96 associated with the transverse edges, 48, 50, 64 and/or 66,respectively.

As described herein, the nonwoven ribbon 32 of an absorbent structure 34can be separated into individual units of fleece 30 which can have thesame absorbent structure 34 as was present in the nonwoven ribbon 32.The fleece 30 can be formed into a blank 28 which can then be compressedinto a pledget 12 of a tampon 10. In various embodiments, the tampon 10can have a cover 138 and a withdrawal aid 14.

In various embodiments a cover 138 can be provided. As used herein, theterm “cover” relates to materials that are in communication with andcover or enclose surfaces of a pledget 12 to prevent the fibrousmaterials of the absorbent structure 34 from directly contacting theinner walls of a woman's vagina and to reduce the ability of portions(e.g., fibers and the like) from becoming separated from the pledget 12or the tampon 10 and being left behind upon removal of the tampon 10from the woman's vagina. In various embodiments, the cover 138 can be afluid-permeable cover 138. By “fluid-permeable” it is meant that bodyfluid is able to pass through the cover 138. The cover 138 can behydrophobic or hydrophilic. By “hydrophilic” it is meant that the cover138 has an affinity for absorbing or tending to combine with water. By“hydrophobic” it is meant that the cover 138 is antagonistic to ortending not to combine with water. The cover 138 can also be treatedwith a surfactant or other material to make it hydrophilic or to make itmore hydrophilic.

The cover 138 can be bonded with: the nonwoven ribbon 32 prior toseparation into individual units of fleece 30, an individual unit offleece 30, a blank 28 which has been formed from a fleece 30, or to thepledget 12 following compression of the blank 28. In an embodiment inwhich the cover 138 is bonded with a pledget 12 following compression ofa blank 28, the cover 138 can be extensible such that the tampon 10 canexpand within the vaginal cavity. In an embodiment in which theabsorbent structure 34 is multi-layered, the cover 138 can be bondedwith at least one layer of the absorbent structure 34 before, after, orwhile the layer of the absorbent structure 34 is bonded to another layerof the absorbent structure 34. The absorbent structure 34 can be in anonwoven ribbon 32 or can be in a fleece 30.

In various embodiments, the cover 138 can be formed from nonwovenmaterials or apertured films. The nonwoven materials can include, butare not limited to, materials such as natural fibers, synthetic fibers,or blends of natural and synthetic fibers. Natural fibers include, butare not limited to, rayon, cotton, wood pulp, flax, and hemp. Syntheticfibers can include, but are not limited to, fibers such as polyester,polyolefin, nylon, polypropylene, polyethylene, polyacrylic, vinylpolyacetate, polyacrylate, cellulose acetate, or bicomponent fibers,such as bicomponent polyethylene and polypropylene fibers. The cover 138can be made by any number of suitable techniques such as, for example,being spunbonded, carded, hydroentangled, thermally bonded, and resinbonded. In an embodiment, the cover 138 can be formed from an aperturedthermoplastic film having either a two-dimensional or athree-dimensional thickness. In an embodiment, the cover 138 can be a 12gsm smooth calendared material made from bicomponent, polyethylenesheath and polyester core, fibers such as Sawabond 4189 available fromSandler AG, Schwarzenbach, Germany. In an embodiment, the cover 138 canbe formed from a single piece of material. In an embodiment, the cover138 can be formed from multiple discrete pieces of material which arebonded together. In an embodiment, the cover 138 can be bleached. In anembodiment, the cover 138 can have a color.

In an embodiment, the cover 138 can be treated with an aqueous solutionto reduce frictional drag, to give the tampon 10 a permanentwettability, to enhance the ease of insertion into and withdrawal from awoman's vagina, and combinations thereof. In an embodiment, the cover138 can be treated either before being rolled or folded up with thefleece 30 into a blank 28 or after the blank 28 has been formed and thecover 138 has been bonded with the blank 28.

In various embodiments, at least a portion of a cover 138 can cover abody facing surface 148, a portion of an interior surface 146, orcombinations thereof of a blank 28. FIG. 25 provides an illustration ofa non-limiting embodiment in which at least a portion of a cover 138 cancover a portion of a body facing surface 148 of a blank 28, such as asoftwind. As illustrated in FIG. 26A, in an embodiment, at least aportion of a cover 138 can cover a portion of an interior surface 146 ofa blank 28 when a fleece 30 is compressed, such as, for example, viaside compression. As illustrated in FIG. 26A, in an embodiment, at leasta portion of the cover 138 can cover a combination of the body facingsurface 148 and the interior surface 146 of a blank 28. The interiorsurface 146 of the blank 28 can result from folding, rolling, orotherwise manipulating the fleece 30 into the blank 28. It is to beunderstood that in an embodiment, the interior surface 146 of thepledget 12 may come into contact with the vaginal walls as the tampon 10can expand when contacted by body fluids. The expansion of the tampon 10can, therefore, cause exposure of the interior surface 146 of thepledget 12 to the vaginal walls and body fluid. As illustrated in FIG.26B, in an embodiment two covers 138 can be in communication with afleece 30 which can be compressed, such as, for example, via sidecompression, into a blank 28. As illustrated in FIG. 26B, in such anembodiment, at least a portion of each of the covers 138 can cover aportion of an interior surface 146 of a blank 28 of a pledget 12. Insuch an embodiment, at least a portion of each of the covers 138 cancover a combination of the body facing surface 148 and the interiorsurface 146 of a blank 28 of a pledget 12. In various embodiments, thecover 138 can extend beyond the withdrawal end 20 of the pledget 12 toform a skirt 150 as illustrated in FIG. 27. It is to be understood that,in an embodiment, the cover 138 can extend beyond the insertion end 18of a pledget 12.

In an embodiment, the cover 138 can have two edges, 152 and 154. Asnoted above, the cover 138 can be bonded to a nonwoven ribbon 32, afleece 30, a blank 28, or a pledget 12. In an embodiment, during thebonding process, at least one of the edges, 152 or 154, of the cover 138can be substantially aligned with one of the transverse edges, such astransverse edges 48 and 50 or 64 or 66. In an embodiment, during thebonding process, the cover 138 can be bonded to the nonwoven ribbon 32,the fleece 30, the blank 28, or the pledget 12 so as to produce a spiralor helical pattern on the resulting pledget 12. In an embodiment, thetwo edges, 152 and 154, can be perpendicular to the longitudinal axis 16of a pledget 12. In an embodiment, the two edges, 152 and 154, can bepositioned in a direction parallel to the longitudinal axis 16 of apledget 12 or at any other angle to the longitudinal axis 16 of apledget 12 such as may occur if the cover 138 is spirally wound aboutthe pledget 12. Thus, while the cover 138 and the edges, 152 and 154,may be discussed herein in an orientation perpendicular to thelongitudinal axis 16 of a pledget 12, one of ordinary skill will be ableto recognize how to provide a cover 138 and edges, 152 and 154, in anorientation parallel with the longitudinal axis 16 of a pledget 12 or inan orientation having any other angle in relation to the longitudinalaxis 16 of a pledget 12.

In an embodiment, the cover 138 can have uniform properties. In anembodiment, the cover 138 can have non-uniform properties. In such anembodiment, the cover 138 can have regions with differing propertieswhich can be coordinated to increase or decrease absorbency and/or levelof expansion of the tampon 10. For example, a region can be morehydrophilic or hydrophobic in comparison to another region of the cover138. In an embodiment, the hydrophilic region of the cover 138 couldsubstantially cover the portion of the tampon 10 that would contact themenses first to increase menses absorption and as a result increaseexpansion of that portion of the tampon 10.

The regions of the cover 138 with differing properties may be producedby various methods. One example of a method is by treating the regionsof the cover 138 with chemical finishes, such as hydrophilic orhydrophobic finishes that make the regions either more hydrophilic ormore hydrophobic, respectively. The regions can also be mechanicallyaltered. Any method known in the art of mechanically altering non-wovensor films can be used. Mechanically altering includes, but is not limitedto, processes such as ring-rolling, corrugating, SELFing, andaperturing.

The composition of the cover 138 can also provide for differingproperties of the cover 138. Different regions of the cover 138 can beproduced from different materials. For example, one region of the cover138 may have a higher concentration of rayon than another section of thecover 138 to make that region more hydrophilic. Materials could beselected for any property desired for a cover 138 known in the art, suchas a selection of a material to provide a region of the cover 138 withgreater extensibility. In an embodiment, the cover 138 may includemultiple discrete pieces that are bonded together to form a single cover138. The discrete pieces can have differing properties such as describedabove. In an embodiment, the discrete pieces of the cover 138 may formthe different regions of the cover 138 such as described above. In suchan embodiment, one discrete piece may form one region and anotherdiscrete piece may form a different region of the cover 138. Thediscrete pieces can be bonded by any method known to one of ordinaryskill in the art, such as sewing, adhesive, thermal bonding, fusionbonding, or combinations thereof.

As illustrated in FIG. 28, in an embodiment, the cover 138 can have atleast one slit 156. In an embodiment, the slit(s) 156 can be locatedbetween the two edges, 152 and 154, of the cover 138. In such anembodiment, the slit 156 can form a cover contact element 162. In anembodiment, the slit(s) 156 can be associated with at least one of theedges, 152 and/or 154. In an embodiment, at least one slit 156 can beassociated with at least one of the edges, 152 and/or 154, and at leastone slit 156 can be located between the two edges, 152 and 154. In anembodiment in which slits 156 are associated with at least one of theedges, 152 and 154, the cover 138 can have at least two slits 156 whichcan form a cover contact element 162. The cover contact element 162 cancome into contact with the walls of the vagina and can direct fluid flowtowards the tampon 10. In an embodiment, the cover 138 can have at leastone cover contact element 162. In an embodiment, the cover 138 can haveat least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 cover contact elements 162. Inan embodiment, the cover 138 can have from about 1, 2, 3, 4, 5, 6, 7, 8,9, or 10 to about 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20 cover contactelements 162. In an embodiment, a cover contact element 162 can beoriented perpendicular to the longitudinal axis 16 of a tampon 10. In anembodiment, a cover contact element 162 can be oriented parallel withthe longitudinal axis 16 of a tampon 10. In an embodiment, a covercontact element 162 can be oriented at any angle as desired to thelongitudinal axis 16 of a tampon 10.

In an embodiment, a slit 156 of the cover 138 can be substantiallyaligned with a slit 96 of a layer(s), such as layer(s) 36 and/or 38. Inan embodiment, a slit 156 can be offset from a slit 96 of a layer(s),such as layer(s) 36 and/or 38. In an embodiment, a slit 156 of a cover138 can be substantially aligned with a slit 96 of a layer(s), such aslayer(s) 36 and/or 38, and a slit 156 of a cover 138 can be offset froma slit 96 of a layer(s), such as layer(s) 36 and/or 38. In thenon-limiting embodiment illustrated in FIG. 28, the slits 156 of thecover 138 can be substantially aligned with the slits 96 of a layer ofthe absorbent structure 34. In such an embodiment, a slit 156 in thecover 138 can allow the contact element 88 to expand in a direction awayfrom the tampon 10 and to deform and flex away from the tampon 10. In anembodiment, the length of a slit 156 in the cover 138 can be any lengthdeemed suitable. In an embodiment, the length of a slit 156 in the cover138 can be substantially similar to the length 98 of a slit 96 in alayer(s), such as layer(s) 36 and/or 38. In an embodiment, a widthbetween two successive slits 156 in the cover 138 can be any width asdeemed suitable. In an embodiment, the width between two successiveslits 156 in the cover 138 can be substantially similar to the width 102between two successive slits 96 in one of the layers, 36 and/or 38. Inan embodiment, the length of a slit 156 and the width between twosuccessive slits 156 in the cover 138 can be substantially similar to ordifferent from the length 98 of a slit 96 and the width 102 betweenslits 96 in a layer(s), such as layer(s) 36 and/or 38, when the slits156 in a cover 138 substantially align with the slits 96 in a layer(s),such as layer(s) 36 and/or 38, or when the slits 156 in a cover 138 areoffset from the slits 96 in a layer(s), such as layer(s) 36 and/or 38.In an embodiment, a cover contact element 162 can substantially alignwith a contact element 88 of a layer(s), such as layer(s) 36 and/or 38.In an embodiment, a cover contact element 162 can be offset from acontact element 88 of a layer(s), such as layer(s) 36 and/or 38.

In various embodiments, the pledget 12 may be subject to furtherprocessing to result in a finished tampon. For example, the pledget 12may be joined with a withdrawal aid 14 and/or applicator.

The withdrawal aid 14 may be attached to the pledget 12 in any suitablemanner. For example, an opening can be formed through the pledget 12(and cover 138 if provided) so as to provide a means for attaching awithdrawal aid 14. In various embodiments, the withdrawal aid 14 can beattached to the fibrous material before or after it is compressed intothe pledget 12. The withdrawal aid 14 can be attached to the fibrousmaterial and then looped upon itself. As illustrated in FIG. 29, thewithdrawal aid 14 can be associated with the nonwoven ribbon 32 and canfurther be associated with the fleece 30. In such an embodiment, thewithdrawal aid 14 can be, as illustrated, wound with the fleece 30 inthe formation of a blank 28. A knot 144 can be formed near the free endsof the withdrawal aid 14 to assure that the withdrawal aid 14 does notseparate from the fibrous material. The knot 144 can also serve toprevent fraying of the withdrawal aid 14 and to provide a location wherea woman can grasp the withdrawal aid 14 when she is ready to remove thetampon 10 from her vagina.

The withdrawal aid 14 can be constructed from various types of threadsor ribbons. A thread or ribbon can be made from 100% cotton fibersand/or other materials in whole or part. The withdrawal aid 14 can bebonded to the absorbent fibers with or without tying. The withdrawal aid14 can have any suitable length and/or the withdrawal aid 14 can be dyedand/or treated with an anti-wicking agent, such as wax, before beingsecured to the pledget 12.

FIG. 29 provides a non-limiting illustration of an embodiment of amethod of manufacturing a blank 28 of the present disclosure. A nonwovenribbon 32 which can have an absorbent structure 34, can ultimatelyresult in a blank 28. In an embodiment, the absorbent structure 34 ofthe nonwoven ribbon 32 can be a single layer. In an embodiment, theabsorbent structure of the nonwoven ribbon 32 can be multi-layered. Theabsorbent structure 34 of the nonwoven ribbon 32, can be manufacturedvia a multi-bank laydown process, a process whereby pre-formed fibrousmaterial layers are bonded together, or a combination thereof. Duringthe manufacture of the absorbent structure 34 of the nonwoven ribbon 32,the absorbent structure 34 can have any configuration of layers asdesired. During the manufacture of a multi-layered absorbent structure34 of a nonwoven ribbon 32, the layers can be configured into anydesired configuration, such as, but not limited to, the configurationsdescribed and illustrated herein. The nonwoven ribbon 32 illustrated inFIG. 29 can have an absorbent structure 34 which can have two layers, 36and 38, which can be placed into communication with each other. In anembodiment, the two layers, 36 and 38, can be bonded to each other afterthey are placed into communication with each other. Each of the layers,36 and 38, can have transverse edges, such as transverse edges 48 and 50of layer 36 and 64 and 66 of layer 38. In the non-limiting illustrationof FIG. 29, transverse edge 50 of first layer 36 can be substantiallyaligned with transverse edge 66 of second layer 38. As illustrated inthe non-limiting illustration of FIG. 29, the first layer 36 can have afirst length 44 which can be longer than a second length 60 of secondlayer 38. As noted herein, the two layers, 36 and 38, can be arrangedinto any desired configuration including, but not limited to, any of theconfigurations described and illustrated herein. As described herein, atleast one slit 96 can be incorporated into at least one of the layers,36 and/or 38, forming the absorbent structure 34 of the nonwoven ribbon32. The slit(s) 96 can be incorporated into at least one of thelayer(s), such as layer(s) 36 and/or 38, prior to, after, or whileplacing one of the layers of the absorbent structure 34 intocommunication with another layer of the absorbent structure 34. In thenon-limiting illustration of FIG. 29, the slit(s) 96 can be associatedwith a transverse edge of one of the layers, 36 and/or 38, such astransverse edge 48 of layer 36. As described herein, in an embodiment,at least one slit 96 can be incorporated into at least one of thelayers, 36 and/or 38, in such a configuration so as to not be associatedwith one of the transverse edges of either of the layers, 36 and/or 38.In the non-limiting embodiment illustrated, a first layer 36 having twotransverse edges, 48 and 50, can be provided and a plurality of slits 96can be associated with transverse edge 48 to form at least one contactelement 88. As discussed herein, in an embodiment, a contact element 88can be associated with any of the transverse edges or can be locatedbetween the transverse edges of a layer. As illustrated in thenon-limiting embodiment shown in FIG. 29, the contact elements 88 can beassociated with transverse edge 48 of layer 36. The nonwoven ribbon 32can also be provided with a cover 138 and a withdrawal aid 14. As notedabove, to create a blank 28, the nonwoven ribbon 32 can be separatedinto individual units of fleece 30. The separation of the nonwovenribbon 32 into individual units of fleece 30 can occur by any suitablemethod such as stretching, perforating, or cutting such as with the useof a die cutter or a knife cutter, and the like. As illustrated in FIG.29, the nonwoven ribbon 32 can be provided with perforation cuts 140which can facilitate the separation of the nonwoven ribbon 32 intoindividual units of fleece 30. The cover 138 can be provided to thenonwoven ribbon 32 before the nonwoven ribbon 32 has been separated intoan individual unit of fleece 30 and can be provided in such a way as tospan at least a portion of the perforation cuts 140.

As noted above, the nonwoven ribbon 32 can be separated into individualunits of fleece 30 which can be rolled, stacked, folded or otherwisemanipulated into blanks 28 before the blanks 28 are formed into pledgets12. For example, suitable menstrual tampons may include “cup” shapedpledgets like those disclosed in U.S. Publication No. 2008/0287902 toEdgett and U.S. Pat. No. 2,330,257 to Bailey; “accordion” or “W-folded”pledgets like those disclosed in U.S. Pat. No. 6,837,882 to Agyapong;“radially wound” pledgets like those disclosed in U.S. Pat. No.6,310,269 to Friese; “sausage” type or “wad” pledgets like thosedisclosed in U.S. Pat. No. 2,464,310 to Harwood; “M-folded” tamponpledgets like those disclosed in U.S. Pat. No. 6,039,716 to Jessup;“stacked” tampon pledgets like those disclosed in U.S. 2008/0132868 toJorgensen; or “bag” type tampon pledgets like those disclosed in U.S.Pat. No. 3,815,601 to Schaefer.

As illustrated in FIG. 29, the fleece 30 can be radially wound into ablank 28, such as a softwind. As illustrated in FIG. 29, the nonwovenribbon 32 can be separated into individual units of fleece 30, which canundergo a radial winding process, illustrated by the partially woundunit 142, to result in a blank 28. A suitable method for making “radialwound” pledgets is disclosed in U.S. Pat. No. 4,816,100 to Friese. Theradial winding method can also include a method for forming the blankinto a pledget like that disclosed in U.S. Pat. No. 6,310,269 to Friese.Suitable methods for making “W-folded” pledgets are disclosed in U.S.Pat. No. 6,740,070 to Agyapong; U.S. Pat. No. 7,677,189 to Kondo; andU.S. 2010/0114054 to Mueller. A suitable method for making “cup”pledgets and “stacked” pledgets is disclosed in U.S. 2008/0132868 toJorgensen.

In various embodiments, the blank 28 can be formed into a pledget 12. Inan embodiment, forming the blank 28 into a pledget 12 can include acompressing step which can utilize any suitable means and apparatus. Forexample, the compressing step may utilize a plurality of dies whichreciprocate relative to one another so as to form a mold cavitytherebetween. When the blank 28 (e.g., a softwind) is positioned withinthe mold cavity, the dies may be actuated so as to move tangent to ortowards one another, tangent to or towards the blank 28 and compress theblank 28. The blank 28 may be compressed any suitable amount. Forexample, the blank 28 may be compressed at least about 25%, 50%, or 75%of the initial dimensions. For example, a blank 28 can be reduced indiameter to approximately ¼ of the original diameter. Thecross-sectional configuration of the resultant pledget 12 may becircular, ovular, rectangular, hexagonal, or any other suitable shape.

In various embodiments, the compressing step may not include anyadditional heat applied to the pledget 12. In other words, the blank 28can be compressed into a pledget 12 without external heat being appliedto the compression equipment or the blank 28. In various embodiments,the compressing step may incorporate or may be followed by one or moreadditional stabilization steps. This secondary stabilization can serveto maintain the compressed shape of the pledget 12. In general, thesecondary stabilization step can create hydrogen bonds between theabsorbent fibers and/or may further strengthen the entanglement of theabsorbent fibers to maintain the shape of the compressed pledget 12.

FIG. 30 provides a non-limiting illustration of an embodiment of amethod of manufacturing a nonwoven ribbon 32 of the present disclosure.A nonwoven ribbon 32 which can have an absorbent structure 34, canultimately result in a blank 28. In an embodiment, the absorbentstructure 34 of the nonwoven ribbon 32 can be a single layer. In anembodiment, the absorbent structure of the nonwoven ribbon 32 can bemulti-layered. As described herein, the absorbent structure 34 of thenonwoven ribbon 32, can be manufactured via a multi-bank laydownprocess, a process whereby pre-formed fibrous material layers are bondedtogether, or a combination thereof. During the manufacture of theabsorbent structure 34 of the nonwoven ribbon 32, the absorbentstructure 34 can have any configuration of layers as desired. During themanufacture of a multi-layered absorbent structure 34 of a nonwovenribbon 32, the layers can be configured into any desired configuration,such as, but not limited to, the configurations described andillustrated herein. The nonwoven ribbon 32 illustrated in FIG. 30 canhave an absorbent structure 34 which can have two layers, 36 and 38,which can be placed into communication with each other. In anembodiment, the two layers, 36 and 38, can be bonded to each other afterhaving been placed into communication with each other. Each of thelayers, 36 and 38, can have transverse edges, such as transverse edges48 and 50 of layer 36 and 64 and 66 of layer 38. In the non-limitingillustration of FIG. 30, transverse edge 50 of first layer 36 can besubstantially aligned with transverse edge 66 of second layer 38. Asillustrated in the non-limiting illustration of FIG. 30, the first layer36 can have a first length 44 which can be longer than a second length60 of second layer 38. As noted herein, the two layers, 36 and 38, canbe arranged into any desired configuration including, but not limitedto, any of the configurations described and illustrated herein. In thenon-limiting embodiment illustrated, a fold 110 can be incorporated intofirst layer 36. The fold 110 can bring transverse edge 48 of layer 36into communication with transverse edge 64 of layer 38. As discussedherein, additional folds can be incorporated into the absorbentstructure 34 as desired and into any configuration as desired. Asdescribed herein, at least one slit 96 can be incorporated into at leastone of the layers, 36 and/or 38, forming the absorbent structure 34 ofthe nonwoven ribbon 32. The slit(s) 96 can be incorporated into at leastone of the layer(s), such as layers 36 and/or 38, prior to, after, orwhile placing one of the layers of the absorbent structure 34 intocommunication with another layer of the absorbent structure 34. In thenon-limiting illustration of FIG. 30, the slit(s) 96 can be associatedwith the fold 110 of first layer 36. As illustrated in FIG. 30, aplurality of slits 96 can be associated with the fold 110 of first layer36 to form at least one contact element 88. As discussed herein, in anembodiment, a contact element 88 can be associated with any of thetransverse edges, a fold, or can be located between the transverse edgesof a layer. As described herein, in an embodiment, at least one slit 96can be incorporated into at least one of the layers, 36 and/or 38, insuch a configuration so as to not be associated with one of thetransverse edges of either of the layers, 36 and/or 38. The nonwovenribbon 32 can also be provided with a cover 138 and a withdrawal aid 14.As noted above, to create a blank 28, the nonwoven ribbon 32 can beseparated into individual units of fleece 30. The separation of thenonwoven ribbon 32 into individual units of fleece 30 can occur by anysuitable method such as stretching, perforating, or cutting such as withthe use of a die cutter or a knife cutter, and the like. As illustratedin FIG. 30, the nonwoven ribbon 32 can be provided with perforation cuts140 which can facilitate the separation of the nonwoven ribbon 32 intoindividual units of fleece 30. The cover 138 can be provided to thenonwoven ribbon 32 before the nonwoven ribbon 32 has been separated intoan individual unit of fleece 30 and can be provided in such a way as tospan at least a portion of the perforation cuts 140.

As illustrated in FIG. 30, the fleece 30 can be radially wound into ablank 28, such as a softwind. As illustrated in FIG. 30, the nonwovenribbon 32 can be separated into individual units of fleece 30, which canundergo a radial winding process, illustrated by the partially woundunit 142, to result in a blank 28. As described herein, in variousembodiments, the blank 28 can be formed into a pledget 12.

In various embodiments, the pledget 12 may be subject to furtherprocessing to result in a finished tampon. For example, the pledget 12may be joined with a withdrawal aid 14, such as described herein, and/orapplicator.

The withdrawal aid 14 may be attached to the pledget 12 in any suitablemanner. For example, an opening can be formed through the pledget 12(and cover 138 if provided) so as to provide a means for attaching awithdrawal aid 14. In various embodiments, the withdrawal aid 14 can beattached to the fibrous material before or after it is compressed intothe pledget 12. The withdrawal aid 14 can be attached to the fibrousmaterial and then looped upon itself. As illustrated in FIGS. 29 and 30,the withdrawal aid 14 can be associated with the nonwoven ribbon 32 andcan further be associated with the fleece 30. In such an embodiment, thewithdrawal aid 14 can be, as illustrated, wound with the fleece 30 inthe formation of a blank 28. A knot 144 can then be formed near the freeends of the withdrawal aid 14 to assure that the withdrawal aid 14 doesnot separate from the fibrous material. The knot 144 can also serve toprevent fraying of the withdrawal aid 14 and to provide a place or pointwhere a woman can grasp the withdrawal aid 14 when she is ready toremove the tampon 10 from her vagina.

In various embodiments, the tampon 10 may also include one or moreadditional features. For example, the tampon 10 may include a“protection” feature as exemplified by U.S. Pat. No. 6,840,927 to Hasse,U.S. 2004/0019317 to Takagi, U.S. Pat. No. 2,123,750 to Schulz, and thelike. In some embodiments, the tampon 10 may include an “anatomical”shape as exemplified by U.S. Pat. No. 5,370,633 to Villalta, an“expansion” feature as exemplified by U.S. Pat. No. 7,387,622 to Pauley,an “acquisition” feature as exemplified by U.S. 2005/0256484 to Chase,an “insertion” feature as exemplified by U.S. Pat. No. 2,112,021 toHarris, a “placement” feature as exemplified by U.S. Pat. No. 3,037,506to Penska, or a “removal” feature as exemplified by U.S. Pat. No.6,142,984 to Brown.

FIGS. 31-40 illustrate one suitable embodiment of an apparatus,indicated generally at 200, and method for making a tampon, and moreparticularly for making a cover, such as a web (or ribbon) of covermaterial used to cover the pledget, such as pledget 12, in forming thetampon 10. As illustrated schematically in FIGS. 31 and 32, theapparatus 200 is for making a web of cover material from a pair of webmaterials, referred to broadly herein as a first or base material and asecond or absorbent material. It is contemplated that the secondmaterial can have other properties in addition to or instead of beingabsorbent, such as, but not limited to wicking and/or wiping.

Materials suitable for the base material and the absorbent material aredescribed above. For example, materials suitable for the base materialcan include materials described above with respect to the cover 138 andmaterials suitable of the absorbent material can include materialsdescribed above with respect to the absorbent structure 34. In onesuitable embodiment, the absorbent material has a tensile strength inthe MD direction of 2-38 Newtons per inch of width, a tensile strengthin the CD direction of 0.13-6 Newtons per inch of width, and a thicknessin the range of 0.25-1 mm. Suitably, the material used for the absorbentmaterial is bondable, has a minimal Poisson's ratio, is hydrophilic, isdrapable and soft, and has minimal linting. In one suitable embodiment,the base material, which is water permeable, has a tensile strength inthe MD direction at of at least 5-75 Newtons per inch of width, atensile strength in the CD direction of 1-20 Newtons per inch. Suitably,the material used for the base material is bondable, has a minimalPoisson's ratio, is drapable and soft, and has minimal linting.

As seen in FIGS. 31 and 32, the apparatus 200 includes a source of basematerial, such as a wound roll 201 comprising a wound or rolledcontinuous web 205 of base material, and a source of absorbent material,such as a wound roll 203 comprising a wound or rolled continuous web 213of absorbent material. It is understood, however, that in otherembodiments other suitable sources 201, 203 of base material and/orabsorbent material may be used (e.g., blocks, boxes, bins, formedin-line).

In an embodiment, the web 205 of base material and the web 213 ofabsorbent material are unwound and moved throughout the apparatus in amachine direction (referenced throughout the various FIGs. as machinedirection MD) (i.e., the direction in which the respective webs aremoved forward through the apparatus). In the illustrated embodiment, theweb 205 of base material has a width sufficient to simultaneously make apair of side-by-side webs of cover material. For example, in oneembodiment, the web 205 of base material has a width in the range of 100mm (about four times the final width of the web of absorbent material)to about 150 mm (about six times the final width of the web of absorbentmaterial), and more particularly about 110 mm. It is contemplated thatthe widths of the webs can be measured using any convention measuringtechnique including rulers, photoeyes, vision cameras, web widthsensors, visual indicators, and combinations thereof.

The web 205 of base material is unwound from the roll 201 in the machinedirection MD by a suitable drive member 211, and passes through atensioning member 209 and guide rolls 207 following unwinding from theroll. Suitable drive members, tensioning members and guide rolls as usedherein are conventional and thus not further described herein except tothe extent necessary to disclose the present invention. The transverse,or cross-direction position of the web is established by the position ofthe unwind equipment (e.g., roll, etc.). Conventional centeringcomponents (e.g., shepherds, hooks, vertical idlers, and other suitablecentering components) may be used to maintain the transverse or CDposition of the web 205 relative to the machine direction MD. Inaddition to guide rolls, other conventional web handling components maybe used to maintain the orientation and centering of the web as it movesthrough the apparatus, such as guide trays and the like. Suitable webguides and web guide controllers are commercially available, such as,the Fife web guiding system.

Thus, both the web 205 of base material and the web 213 of absorbentmaterial are registered in both the MD and CD direction. In other words,both of the webs 205, 213 are aligned relative to one or more referencepoints. The one or more reference points can be a portion of the web205, 213 itself, a portion of the other web, a component (or portionthereof) of the apparatus 200, and/or combinations thereof. In onesuitable embodiment, CD registration of the webs 205, 213 is maintainedwithin ±0-5 mm, and MD registration of webs is maintained within ±0-2mm. The web 213 of absorbent material is centered at its desiredlocation on the web 205 of base material within ±0-5 mm. Suitably, oneor more inspection systems can be used to ensure proper CD and MDregistration of the webs 205, 213.

In the illustrated embodiment, the web 213 of absorbent material on theroll 203 has a width sufficient to simultaneously make a pair ofside-by-side webs of cover material. However, the width of the web 213of absorbent material, in one embodiment, is also narrower than thewidth of the web 205 of base material. For example, in one embodimentthe width of the web 213 of absorbent material on the roll 203 is in therange of about 25 mm to about 70 mm, and more particularly about 50 mm.In other embodiments, the web 205 of base material and the web 213 ofabsorbent material may have respective widths sufficient to make asingle web of cover material, or more than two side-by-side webs ofcover material. It is also contemplated that in other embodiments therelative widths of the web 205 of base material and the web 213 ofabsorbent material may be other than as described above.

The web 213 of absorbent material on the roll 203 is unwound from theroll in the machine direction thereof by a suitable drive member 221,and passes through a tensioning member 219 and guide rolls 217 followingunwinding from the roll. The transverse, or cross-direction position ofthe web 213 is established by the position of the unwind equipment(e.g., roll, etc.). Conventional centering components (e.g., shepherds,hooks, vertical idlers, and other suitable centering components) may beused to maintain the transverse position of the web 213 relative to themachine direction MD. In addition to guide rolls, other conventional webhandling components may be used to maintain the orientation andcentering of the web 213 as it moves through the apparatus, such asguide trays and the like. Suitable web guides and web guide controllersare commercially available, such as, the Fife web guiding system.

A subsequent drive member 223 further moves the web 213 through aslitter 225 where the web of absorbent material is slit longitudinally(i.e., in the machine direction of the web) to form two separateside-by-side webs 213 a, 213 b of absorbent material, each correspondingto what will become a respective web of cover material upon associationwith the base material. The pair of absorbent material webs 213 a, 213 bis further passed over a series of turn rolls 227 to re-orient the websand space them apart to a desired alignment for subsequent overlaymentwith the web 205 of base material. It is understood that the turn rolls227 can be other suitable devices including, but not limited to, fifeguides, guide trays. The webs 213 a, 213 b of absorbent material aredirected over additional guide rolls, to the drive member 223 at whichthe webs of absorbent material are overlayed onto the web 205 of basematerial. It is contemplated that the webs 213 a, 213 b of absorbentmaterial can be overlayed onto the web 205 of base material before orafter the drive member 223. In one suitable embodiment, the webs 213 a,213 b of absorbent material are overlayed onto the web 205 of basematerial at a bonder anvil.

Tension in each of the webs 205, 213, in one embodiment, is establishedusing conventional devices, such as the respective drive members 211,221, 223, spindle friction (not shown), dancer roll 209, 219, closedloop tension feedback device (not shown) and/or other suitable tensioncontrol devices. Web tensioning provides appropriate material strain ineach of the webs 205, 213 to prevent wrinkling, curl and/or tearingduring processing, and provides appropriate strain match duringsubsequent combining of the webs as described later herein.

With reference to FIG. 34, in one embodiment the webs 213 a, 213 b ofabsorbent material are overlayed onto the single web 205 of basematerial in transversely spaced (relative to the machine direction MD ofthe web) relationship with each other, but transversely inward fromrespective side edges 231 of the web of base material to allow forsubsequent folding of the web of base material. For example, in oneembodiment, the webs 213 a, 213 b of absorbent material are transverselyspaced in the range of about 90 mm to about 130 mm from each other, andmore particularly about 100 mm. The webs 213 a, 213 b are transverselyspaced from the respective side edges 231 of the web 205 of basematerial a distance of about 0 mm to about 55 mm and more particularlyabout 55 mm, the reasons for which will become apparent. It isunderstood that the webs 213 a, 213 b of absorbent material can betransversely spaced from each and the respective side edge 231 by othersuitable distances. The respective speeds of the webs 205, 213, i.e.,the speed of movement in the machine direction MD, at the instant ofoverlayment are, in one embodiment, equal. In another embodiment, thewebs 205, 213 may be moving at different speeds as overlayment occurs.The speeds of the webs 205, 213 can be controlled, for example, by servomotors, mechanical linkages, and the like.

It is contemplated that the webs 213 a, 213 b of absorbent material canbe placed beneath the web 205 of base material or that the web of basematerial can be overlayed onto webs 213 a, 213 b of absorbent material.It is also contemplated that the webs 213 a 213 b of absorbent materialcan be placed on opposite faces of the web 205 of base material. Forexample, one of the webs 213 a of absorbent material can be placedbeneath the web 205 of base material and the other web 213 b ofabsorbent material can be overlayed onto the web of absorbent material.

The overlayed webs 213 a, 213 b of absorbent material and web 205 ofbase material are then moved by a suitable drive member 233 through abonding apparatus 235 for a bonding operation (broadly, a firstsecurement) in which the webs of absorbent material are bonded (i.e.,secured) to the web of base material. The bonding can occur by anymethod deemed suitable including, but not limited to, adhesives, heatbonding, vibration energy, mechanical bonding, chemical bonding, vacuumbonding, ultrasonic bonds, thermal bonds, pressure bonds, mechanicalentanglement, hydroentanglement, microwave bonds, or any otherconventional technique. The bonding can be continuous or it can beintermittent.

In one embodiment, the bonding apparatus is suitable for autogenousbonding, which as used herein means bonding provided by fusion and/orself-adhesion of fibers and/or filaments without an applied externaladhesive or bonding agent. Autogenous bonding can be provided by contactbetween fibers and/or filaments while at least a portion of the fibersand/or filaments are semi-molten or tacky. Autogenous bonding may alsobe provided by blending a tackifying resin with the thermoplasticpolymers used to form the fibers and/or filaments. Fibers and/orfilaments formed from such a blend can be adapted to self-bond with orwithout the application of pressure and/or heat. Solvents may also beused to cause fusion of fibers and filaments which remain after thesolvent is removed.

In one embodiment, the autogenous bonding is thermal point bonding, orpattern bonding, conducted by a suitable thermal point bonding apparatus235 which involves passing the web between a heated calendar roll and ananvil roll. The calendar roll is usually, but not always, patterned insome way so that the entire fabric is not bonded across its entiresurface, and the anvil roll is usually flat. As a result, variouspatterns for calendar rolls have been developed for functional as wellas aesthetic reasons. For example, in the illustrated embodiment, theapparatus 235 bonds the webs 213 a, 213 b of absorbent materials to theweb 205 of base material along a predetermined pattern of point bonds,such as the pattern of staggered point bonds 237 illustratedschematically in FIGS. 35 and 36. Other potential point bond patternsinclude staggered dashes, curved bond lines, or a combination ofabstract, geometrical or realistic shapes and objects. Securing the webs213 a, 213 b of absorbent materials to the web 205 of base material atthis stage of manufacture allows for subsequent folding and processingof the webs while maintaining desired registration and alignmenttherebetween. In other embodiments, the first securement may be providedby thermal bonding, adhesive bonding or other suitable securementtechniques. It is also understood that, in some embodiments, the webs213 a, 213 b of absorbent material can be held in registration with theweb 205 of base material using other suitable methods (e.g., vacuumconveyors).

Following this first securement operation, the secured webs 213 a, 213b, 205 of absorbent material and base material together form a web 239of cover material that in the illustrated embodiment is actually a pairof side-by-side (and at this stage connected) webs of cover material.The web 239 of cover material is then drawn by the drive member 233through a folding station, which is generally indicated at 241. All ofthe folding stations of the illustrated apparatus 200 perform webalignment by creating a repeatable folded edge ensuring CD alignment ofthe web. In one embodiment, the folding station 241 is configured tofold transversely outward segments 243 of base material transverselyinward over the entire respective web 213 a, 213 b of absorbent materialto substantially enclose the web of absorbent material between opposedlayers of the web of base material. Suitable folding devices include,without limitation, folding boards, folding skis, folding fingers, GEOfolder and the like and combinations thereof. Additionally in anembodiment, the folding station 241 and first securement are designed tofold the web 205 of base material tightly around and in constant contactwith the webs 213 a, 231 b of absorbent material. Thus, the web 205 ofbase material is inhibited from puckering, wrinkling or otherwisemisalignment with the webs 213 a, 213 b of absorbent material.

FIG. 37 schematically illustrates the cross-section of the web 239 ofcover material following folding at this folding station 241. In thisembodiment, the inward folded transverse segments of the web 205 of basematerial extend transversely inward beyond inner side edges 245 of therespective webs 213 a, 213 b of absorbent material such that a portionof the opposed layers of the base material web face each other withoutany web of absorbent material therebetween. In other embodiments, thetransverse segments of the web 205 of base material may extendtransversely inward to the respective inner side edges 245 of the webs213 a, 213 b of absorbent material, or extend short of the respectiveinner side edges of the webs of absorbent material.

The folded web 239 of cover material is subsequently drawn by a suitabledrive member 247 through another folding station, generally indicated at251, for additional folding. Suitable folding devices include, withoutlimitation, folding boards, folding skis, folding fingers, GEO folderand the like and combinations thereof. In one embodiment, as illustratedschematically in FIG. 38, the already folded portion of the web 239 ofcover material is further folded transversely inward upon itself. Moreparticularly, it is folded over such that the web 213 a, 213 b ofabsorbent material is folded generally in half. In other embodiments,the already folded portion of the web 239 of cover material may befolded over upon itself more or less than illustrated in FIG. 38 withoutdeparting from the scope of this invention.

The folded web 239 of cover material is directed through a securementstation, generally indicated at 255, comprising a bonding apparatus fora second bonding operation (broadly, a second securement) in which thewebs 213 a, 213 b, 205 of absorbent material and base material arebonded (i.e., secured) together at the folded portions thereof in orderto secure the web of cover material in its folded configuration. Thebonding can occur by any method deemed suitable including, but notlimited to, adhesives, heat bonding, vibration energy, mechanicalbonding, chemical bonding, vacuum bonding, ultrasonic bonds, thermalbonds, pressure bonds, mechanical entanglement, hydroentanglement,microwave bonds, or any other conventional technique. The bonding can becontinuous or it can be intermittent.

In one embodiment, the bonding apparatus is suitable for autogenousbonding. In an embodiment, the autogenous bonding is ultrasonic bondingperformed by suitable ultrasonic bonding apparatus 255 thatultrasonically bonds all of the layers of the folded portions of the web239 of cover material together in a predetermined bond pattern. Forexample, in the illustrated embodiment the apparatus 255 bonds the webs213 a, 213 b, 205 of absorbent material and base material together atthe folded portions thereof along a predetermined pattern of pointbonds, such as the repeating but otherwise non-uniform (i.e., notsymmetric in the machine direction and/or the transverse direction)snail-shaped pattern of point bonds illustrated schematically in FIG.39. Other potential point bond patterns include staggered dots and/ordashes, curved bond lines, or a combination of abstract, geometrical orrealistic shapes and objects. In other embodiments, the bond pattern maybe any suitable bond pattern. For example, the bond pattern may beanother suitable non-uniform bond pattern, or it may be any suitableuniform bond pattern.

The bond pattern in one embodiment is sufficient to provide an adequatenumber of bonds, or adequate bonded surface area, for each of thelater-formed contact elements 162 (FIG. 28), e.g., formed by the slits156 in the cover 138. In an embodiment, the bond pattern may besufficient to provide an equal number of point bonds, or an evendistribution of bonded surface area, over each of the later-formedcontact elements 162. In another embodiment, the bond pattern mayprovide an unequal number of point bonds, or a non-uniform distributionof bonded surface area, over multiple later-formed contact elements 162.

In an embodiment, this second bonding (i.e., second securement)operation provides a bond having a bond strength that is greater thanthe bond strength provided by the first bonding (i.e., first securement)operation. It is understood that the bond strength, for example, can becontrolled by pressure, energy, temperature, time and pattern used inthe bonding process. For example, in the illustrated embodiment, thebond pattern provided by this second bonding operation has a higher bondpoint density and/or a higher bonded surface area than the bond patternprovided by the first bonding operation. In addition, the second bondingoperation of the illustrated embodiment is operated at a temperaturesufficient to melt the webs 213 a, 213 b of absorbent material and tothe web 205 of base material whereas the first bonding operation is notoperated at such a temperature.

In an embodiment, as illustrated in FIG. 33, the securement stationfurther comprises an additional bonding apparatus 261. In theillustrated embodiment, the additional bonding apparatus 261 is also anultrasonic bonding apparatus and is operable to bond the folded portionsof the web 239 of cover material at a location that is at least in partdifferent from the location at which the bond pattern is applied by theupstream bonding apparatus. More particularly, this bonding apparatus261 bonds at least the folded portion of the web 205 of base material atwhich the opposed layers of base material face each other withoutintervening absorbent material therebetween. In one embodiment, asillustrated in FIG. 40, this additional bonding apparatus 261additionally bonds all of the layers of the folded portion of the web239 of cover material together generally along the inner side edges 245of the respective webs 213 a, 213 b of absorbent material. Thisadditional bonding operation securely encloses the webs 213 a, 213 b ofabsorbent material within the folded web 205 of base material.

In one embodiment, the bond pattern produced by this additional bondingoperation is a uniform, generally sinusoidal (e.g., wave) bond pattern.In other embodiments, the bond pattern produced by this additionalbonding operation may be any suitable uniform or non-uniform bondpattern. For example, in one embodiment, the bond pattern is anintermittent, offset stitch pattern to inhibit CD movement of the web asit passes through the apparatus 200. The bond strength provided by thisadditional bonding operation is also greater than the bond strengthprovided by the first bonding (i.e., first securement) operation.

Downstream of the securement station, the folded and bonded web 239 ofcover material is subsequently drawn through a slitter 271 which isoperable to slit the web of cover material into two discrete,side-by-side webs of cover material (FIGS. 31 and 33). For example, theweb 239 of cover material may be slit along the transverse mid-point ofthe web, transversely inward of each of the folded portions of the web.In such an embodiment, each web 239 of cover material thus includes afolded portion and an unfolded portion comprised only of the basematerial.

In the embodiment illustrated in FIGS. 31 and 33, the webs 239 a, 239 bof cover material are further drawn through a die cutter 273 or othersuitable cutting apparatus. The die cutter 273 is operable to cut slitsin the folded portion of each of the webs of cover material, such as toform the slits 156 and corresponding contact elements 162 of theembodiment of FIG. 28. In an embodiment, the die cutter 273 may beoperable to cut the slits in a pattern in which a set of equally spacedslits is cut into the folded portions of the webs 239 of cover materialalong a segment corresponding to the length of cover material to beapplied to a single pledget to form a single tampon, followed by arelatively larger gap before the next set of equally spaced slits alonga segment corresponding to the next length of cover material to appliedto another pledget to form another tampon. In this embodiment, the gapcan be used as a point of registration during further processing (e.g.,cutting, bonding) of the webs 239 a, 239 b of cover material.

In another embodiment, which is illustrated in FIG. 41, the die cutter273 may be operable to cut the slits 96 such that each slit is equallyspaced in the folded portions of the webs 239 of cover material along asegment P1 corresponding to the length of cover material to be appliedto a single pledget to form a single tampon, followed by the next set ofequally spaced slits along a segment P2 corresponding to the next lengthof cover material to applied to another pledget to form another tampon.Thus, in this embodiment, each tampon 10 has the same number of contactelements 196 and each of the contact elements 196 has the same width Wand the same length L1. In the illustrated embodiment, for example, eachof the tampons 10 formed from the web 239 would have seven complete(i.e., whole) contact elements 196. It is understood, however, thatnumber of contact elements 196 per tampon 10, the width W of each of thecontact elements, and length L1 of each of the contact elements candiffer. In yet another embodiment, the die cutter 273 may be omittedfrom the apparatus 200. In such an embodiment, the slits 96 can beformed in a later process as described in more detail below.

In an embodiment, after passing the die cutter 273 (or the slitter 271if the die cutter is omitted) the webs 239 a, 239 b of cover materialare wound onto respective rolls (not shown) for subsequent transport toa tampon making apparatus where the webs of cover material are each cutinto discrete webs of cover material and applied about the circumferenceof an absorbent structure, such as a pledget 12, to form a tampon. Inone suitable embodiment, one or both of the webs 239 a, 239 b of covermaterial is turned over about its centerline longitudinally before beingwound into a roll. Winding of the webs 239 a, 239 b of cover material,in one suitable embodiment, can be done in a traverse spooling patternand can be controlled (e.g., by steering devices, servos) such that thecontinuous longitudinal support structure of the web (unslit portion, orfolded portion depending on die cutter placement) is registered toadjacent windings in the CD and radial layers in order to provide rollstability and prevent damage to the webs including any contact elements.

FIGS. 42-50 illustrate another embodiment of an apparatus, indicatedgenerally at 300, and method for making a tampon, and more particularlyfor making a cover, such as a web (or ribbon) of cover 138 used to coverthe pledget, such as pledget 12, in forming the tampon. In thisembodiment, a folding station, generally indicated at 381 in FIGS. 42and 43, is disposed adjacent and prior to the drive member 223 (afterthe web 213 of absorbent material is split into the pair of side-by-sidewebs 213 a, 213 b of absorbent material) and the joint drive roll 229(at which the webs of absorbent material are overlaid onto the web 205of base material) in the machine direction of the webs of absorbentmaterial. Suitable folding devices include, without limitation, foldingboards, folding skis, folding fingers, GEO folder and the like andcombinations thereof. At this initial folding station 381, each of thewebs 213 a, 213 b of absorbent material is folded transversely inwardupon at least a portion of itself. For example, in one embodiment,illustrated in FIG. 45, the transversely outermost one-third of each ofthe webs 213 a, 213 b of absorbent material is folded transverselyinward at this initial folding station. In other embodiments, more orless than one-third of the outermost portion of each web 213 a, 213 b ofabsorbent material may be folded transversely inward over anotherportion thereof. In other embodiments, an innermost portion of each web213 a, 213 b of absorbent material may be folded transversely outwardover another portion thereof, or both an innermost portion and anoutermost portion of each web of absorbent material may be folded overanother portion thereof.

The initially folded webs 213 a, 213 b of absorbent material are thendrawn over the joint drive roll 229 where the webs of absorbent materialare overlaid onto the web 205 of base material in transversely spaced(relative to the machine direction of the web) relationship with eachother, but transversely inward from the respective side edges 231 of theweb of base material (as illustrated in the embodiment of FIG. 46) forreasons which will become apparent. For example, in one embodiment thewebs 213 a, 213 b of absorbent material are transversely spaced in therange of about 0 mm to about 55 mm from each other, and moreparticularly about 2 mm. The webs 213 a, 213 b are transversely spacedfrom the respective side edges 231 of the web 205 of base material adistance of about 0 mm to about 10 mm and more particularly about 3 mm.

The overlayed webs 213, 205 of absorbent material and web of basematerial are then moved by the drive member 233 through the bondingapparatus 235 for a bonding operation (broadly, a first securement) inwhich the webs of absorbent material are bonded (i.e., secured) to theweb of base material. As discussed above, in one embodiment the bondingapparatus is a point bonding apparatus that bonds the webs of absorbentmaterials to the web of base material along a pattern of point bonds 237as illustrated schematically in FIGS. 46 and 47. Securing the webs 213a, 213 b of absorbent material to the web 205 of base material at thisstage of manufacture allows for subsequent folding and processing of thewebs while maintaining desired registration and alignment therebetween.In other embodiments, the first securement may be provided by thermalbonding, adhesive bonding or other suitable securement techniques.

With reference to FIGS. 42 and 44, following this first securementoperation, the secured webs 213, 205 of absorbent material and basematerial together form a web 239 of cover material that in theillustrated embodiment is actually a pair of side-by-side (and at thisstage connected) webs 239 a, 239 b of cover material. The web 239 ofcover material is then drawn by the drive member 247 through the foldingstation, generally indicated at 251. In one embodiment this foldingstation 251 is configured to fold each of the initially folded webs 213a, 213 b of absorbent material transversely inward over at least anotherportion of itself to define three layers of the folded absorbentmaterial as illustrated in FIG. 48. The web 205 of base materialunderlying each of the folded portions of the webs 213 a, 213 b ofabsorbent material is folded along with the webs of the absorbentmaterial, with the side edges 231 of the web of base material extendingtransversely inward beyond the inner side edges 245 of the folded websof absorbent material such that a portion of opposed layers of the basematerial web face each other without any absorbent materialtherebetween. In other embodiments, the webs 213 a, 213 b of absorbentmaterial may be folded other than in segments of equal width. In anotherembodiment, the side edges 231 of the web 205 of base material mayextend transversely inward to the respective inner side edges 245 of thewebs 213 a, 213 b of absorbent material, or extend short of therespective inner side edges of the webs of absorbent material.

The drive member 253, which is disposed downstream of the foldingstation 251, also draws the folded web 239 of cover material through asecurement station, generally indicated at 254, comprising a bondingapparatus 255 for a second bonding operation (broadly, a secondsecurement) in which the webs 213, 205 of absorbent material and basematerial are bonded (i.e., secured) together at the folded portionsthereof in order to secure the web of cover material in its foldedconfiguration. In one embodiment, the bonding apparatus 255 is anultrasonic bonding apparatus that ultrasonically bonds all of the layersof the folded portions of the web of cover material together in apredetermined bond pattern 257. In one embodiment, illustrated in FIG.49, the bond pattern is a generally non-uniform bond pattern (i.e., notsymmetric in the machine direction and/or the transverse direction),such as the illustrated snail-shaped bond pattern. In other embodiments,the bond pattern may be any suitable bond pattern. For example, the bondpattern may be another suitable non-uniform bond pattern, or it may beany suitable uniform bond pattern.

The bond pattern in one embodiment is sufficient to provide an adequatenumber of bonds, or adequate bonded surface area, for each of thelater-formed contact members 162 (FIG. 28), e.g., formed by the slits156 in the cover 138. In an embodiment, the bond pattern may besufficient to provide an equal number of point bonds, or an evendistribution of bonded surface area, over each of the later-formedcontact elements 162. In another embodiment, the bond pattern mayprovide an unequal number of point bonds, or a non-uniform distributionof bonded surface area, over multiple later-formed contact elements 162.

In an embodiment, this second bonding (i.e., second securement)operation provides a bond having a bond strength that is greater thanthe bond strength provided by the first bonding (i.e., first securement)operation. It is understood that the bond strength can be controlled bypressure, energy, temperature, time and pattern used in the bondingprocess. For example, in the illustrated embodiment the bond patternprovided by this second bonding operation has a higher bond pointdensity, and thus a higher bonded surface area, than the bond patternprovided by the first bonding operation.

In an embodiment, as illustrated in FIGS. 42 and 44, the securementstation 254 further comprises the additional bonding apparatus 261. Inthe illustrated embodiment, the additional bonding apparatus 261 is alsoan ultrasonic bonding apparatus and is operable to bond the foldedportions of the web 239 of cover material at a location that is at leastin part different from the location at which the bond pattern 257 isapplied by the upstream bonding apparatus. More particularly, thisbonding apparatus 261 bonds at least the folded portion of the web 205of base material at which the opposed layers of base material face eachother without intervening absorbent material therebetween. In oneembodiment, as illustrated in FIG. 50, this additional bonding apparatus261 additionally bonds all of the layers of the folded portion of theweb 239 of cover material together generally along the inner side edges245 of the respective webs 213 a, 213 b of absorbent material. Thisadditional bonding operation securely encloses the webs 213 a, 213 b ofabsorbent material within the folded web 205 of base material. It iscontemplated that the bonding apparatus 261 can be any suitable bondingapparatus including, for example, a stitching or sewing apparatus.

In one embodiment, the bond pattern 263 produced by this additionalbonding operation is a uniform, generally sinusoidal (e.g., wave) bondpattern. In other embodiments, the bond pattern 263 produced by thisadditional bonding operation may be any suitable uniform or non-uniformbond pattern. For example, in one embodiment, the bond pattern is anintermittent, offset stitch pattern to inhibit CD movement of the web asit passes through the apparatus 200. The bond strength provided by thisadditional bonding operation is also greater than the bond strengthprovided by the first bonding (i.e., first securement) operation.

Downstream of the securement station 254, the folded and bonded web 239of cover material is subsequently drawn through the slitter 271 which isoperable to slit the web of cover material into two discrete,side-by-side webs 239 a, 239 b of cover material. For example, the web239 of cover material may be slit along the transverse mid-point of theweb, transversely inward of each of the folded portions of the web. Insuch an embodiment, each web 239 a, 239 b of cover material thusincludes a folded portion and an unfolded portion comprised only of thebase material.

In the embodiment illustrated in FIGS. 42 and 44, the webs 239 a, 239 bof cover material are further drawn through the die cutter 273 or othersuitable cutting apparatus. The die cutter 273 is operable to cut slitsin the folded portion of each of the webs of cover material, such as toform the slits 156 and corresponding contact elements 162 of theembodiment of FIG. 28. In one suitable embodiment, the die cutter 273may be operable to cut the slits 96 in a pattern in which a set ofequally spaced slits is cut into the folded portions of the webs ofcover material along a segment corresponding to the length of covermaterial to be applied to a single pledget to form a single tampon,followed by a relatively larger gap before the next set of equallyspaced slits along a segment corresponding to the next length of covermaterial to applied to another pledget to form another tampon.

In another embodiment, which is illustrated in FIG. 41, the die cutter273 may be operable to cut the slits 96 such that each slit is equallyspaced in the folded portions of the webs 239 of cover material along asegment P1 corresponding to the length of cover material to be appliedto a single pledget to form a single tampon, followed by the next set ofequally spaced slits along a segment P2 corresponding to the next lengthof cover material to applied to another pledget to form another tampon.Thus, in this embodiment, each tampon 10 has the same number of contactelements 196 and each of the contact elements 196 has the same width Wand the same length L1. In the illustrated embodiment, for example, eachof the tampons 10 formed from the web 239 would have seven complete(i.e., whole) contact elements 196. It is understood, however, thatnumber of contact elements 196 per tampon 10, the width W of each of thecontact elements, and length L1 of each of the contact elements candiffer. In yet another embodiment, the die cutter 273 may be omittedfrom the apparatus 300. In such an embodiment, the slits 96 can beformed in a later process as described in more detail below.

In an embodiment, after passing the die cutter 273 (or the slitter 271if the die cutter is omitted) the webs 239 a, 239 b of cover materialare wound onto respective rolls (not shown) for subsequent transport toa tampon making apparatus where the webs of cover material are each cutinto discrete lengths of cover material and applied about thecircumference of an absorbent structure, such as a pledget 12, to form atampon.

FIG. 51 schematically illustrates one suitable embodiment of anapparatus, indicated generally at 400, for making the tampon 10. As seenin FIG. 51, a web 490 (e.g., a web of material suitable for the fleece30 of the tampon 10) is fed from a suitable supply source (e.g., supplytub 492). In the illustrated embodiment, the web 490 (broadly, “asubstrate”) is fed from the supply tub 492 by a first web transferdevice, indicated generally at 402, to an assembly station, indicatedgenerally at 404.

While the illustrated embodiment of the apparatus 400 shows the websupply source as being the supply tub 492, it is understood that anysuitable supply source (e.g., a roll, a barrel) can be used. It is alsounderstood that the web 490 can be formed in-line. For example, the web490 could be formed using any suitable web forming technique, such as acarding line, and fed directly to the web transfer device (not shown)upon its formation.

The first web transfer device (not shown) is adapted to draw the web 490from the supply tub 492 at a predetermined rate (i.e., speed) and undera predetermined amount of tension. Web tensioning can suitably beestablished via the use of conventional tensioning devices (e.g.,spindle friction, dancer roll, drive rolls, closed loop tension feedbackdevice, and the like). The first web transfer device 402 also aligns theweb 490 in the cross-machine direction (CD direction). In one suitableembodiment, the first web transfer device 402 aligns the web 490generally along a machine centerline. As mentioned above, the web 490 isfed by the first web transfer device 402 to the assembly station 404.

The transverse, or cross-direction position of the web 490 isestablished by the position of the unwind equipment (e.g., roll, etc.).Conventional centering components (e.g., shepherds, hooks, verticalidlers, and other suitable centering components) may be used to maintainthe transverse or CD position of the web 490 relative to the machinedirection MD. In addition to guide rolls, other conventional webhandling components may be used to maintain the orientation andcentering of the web as it moves through the apparatus, such as guidetrays and the like. Suitable web guides and web guide controllers arecommercially available, such as, the Fife web guiding system.

At the assembly station 404, the web 490 is perforated in thecross-machine direction at predetermined intervals to define transverselines of weakness 405 in the web (FIG. 54). In one suitable embodiment,the assembly station 404 is configured to perforate the web 490 todefine the transverse line of weakness 405 approximately every 256 mm ofweb. That is, in one embodiment, the lines of weakness 405 are spacedapart approximately every 256 mm along the length of the web 490. It isunderstood that the lines of weakness 405 can be formed in othersuitable ways besides perforating the web 490. For example, the lines ofweakness 405 can be formed by embossing, scoring, and/or combinationsthereof. It is also understood that the lines of weakness 405 can bespaced apart any suitable distance along the length of the web 490. Theweb 490 having one of the lines of weakness 405 defined by a pluralityof perforations is illustrated in FIG. 54

Simultaneously, a web (or multiple webs) 494 of suitable cover materialis provided from a suitable supply source (e.g., supply roll 496). Inthe illustrated embodiment, the web 494 is fed from the supply roll 496through a web guide device, indicated generally at 406, to the assemblystation 404. In one suitable embodiment, the web 494 of cover materialis fed in the machine direction and generally aligned with the web 490of fleece material. It is understood, however, that one or both of thewebs 490, 494 can be fed to the apparatus 400 at any suitable angleincluding, for example, the cross-section direction. While theillustrated embodiment of the apparatus 400 shows the web supply sourceas being the supply roll 496, it is understood that any suitable supplysource (e.g., a tub, a barrel) can be used. It is also understood thatthe web 494 can be formed in-line. For example, the web 494 could beformed using the apparatus and methods described above.

As seen in FIG. 52, which is a cross-section taken transversely (i.e.,in the cross-machine direction) through the web 494, the web in onesuitable embodiment comprises a base web 498 and an absorbent web 408carried by the base web. In the illustrated embodiment, the base web 498is a continuous web of material suitable for covering the fleece 30 ofthe tampon 10. It is understood that the base web 498 can have othersuitable properties in addition to or instead of being absorbent, suchas, for example cleaning and/or wiping. The absorbent web 408 can be acontinuous web or a discontinuous web (i.e., discrete pieces) of asuitable absorbent material that is bonded at one end to the base web498. Thus, the absorbent web 408 has a bonded end 410 and a free end 412spaced from the bonded end. The free end 412 of the absorbent web 408can move (e.g., by pivoting the absorbent web about the bonded end 410)relative to the base web 498. It is contemplated that in someembodiments the base web 498 and the absorbent web 408 can be formed asa single, integrated web. It is also contemplated that in someembodiments the absorbent web 408 can be bonded to the base web 498through the full width (CD direction) of the absorbent web. It isfurther contemplated that in other embodiments the absorbent web 408 canbe free from bonding to the base web 498.

With reference now to FIG. 53, which is a fragmentary top view of theweb 494, the absorbent web 408 has a plurality of slits 96, which areprovided to form the contact elements 88 of the tampon 10. As mentionedabove, it is contemplated that other components of the tampon 10 canhave slits 96 for forming the contact elements 88 of the tampon 10. Itis also contemplated that the slits 96 can be preformed (i.e., formedbefore web 494 is to be used as the supply roll 496) or formed duringthe manufacturing of the tampon 10 as described in more detail below.

With reference again to FIG. 51, the second web transfer device 406 isadapted to draw the web 494 from the supply roll 496 at a predeterminedrate (i.e., speed) and under a predetermined amount of tension. Webtensioning can suitably be established via the use of conventionaltensioning devices (not shown) (e.g., spindle friction, dancer roll,drive rolls, closed loop tension feedback device, and the like). In onesuitable embodiment, a second web transfer device (not shown) is adaptedto control the wrinkling and/or to remove wrinkles present in one orboth of the webs 494, 490. Web tensioning also provides the appropriatestrain match during the combining of the webs 490, 494.

It is also contemplated that the second web transfer device 406 can beconfigured to detect splices or other defects in the web 494, tocontrol/remove dust from the web, and/or to inhibit static charges frombuilding up in the web. The second web transfer device 406 also alignsthe web 494 in the cross-machine direction (CD direction). In onesuitable embodiment, the second web transfer device 406 aligns the web494 with the other web 490 (i.e., the web of fleece 30 material)generally along the machine centerline.

The transverse, or cross-direction position of the web 494 isestablished by the position of the unwind equipment (e.g., roll, etc.).Conventional centering components (e.g., shepherds, hooks, verticalidlers, and other suitable centering components) may be used to maintainthe transverse or CD position of the web 494 relative to the machinedirection MD. In addition to guide rolls, other conventional webhandling components may be used to maintain the orientation andcentering of the web as it moves through the apparatus, such as guidetrays and the like. Suitable web guides and web guide controllers arecommercially available, such as, the Fife web guiding system.

Thus, both of the webs 490, 494 are registered in both the MD and CDdirection. In other words, both of the webs 490, 494 are alignedrelative to one or more reference points. The one or more referencepoints can be a portion of the web 490, 494 itself, a portion of theother web, a component (or portion thereof) of the apparatus 400, and/orcombinations thereof. In one suitable embodiment, CD registration is ±2mm and MD registration is ±3 mm of the webs 490, 494 and can be measuredby Photoeyes, vision system, visual indicators, rulers, and otherconventional measuring techniques.

As mentioned above, the web 494 of cover material is fed from the secondweb transfer device (not shown) to the assembly station 404. At theassembly station 404, the web 494 is cut or perforated in thecross-machine direction into discrete web segments 414 having apredetermined length L (FIG. 54). In the illustrated embodiment, forexample, each of the web segments 414 have a length of approximately 128mm. It is understood that the web segments 414 can be cut into anysuitable lengths.

During the cutting process, the absorbent web 408 of the web 494 iscontrolled to ensure that it is cut properly along with the base web494. In one suitable embodiment, the absorbent web 408 is held againstthe base web 494 by a suitable hold down device to maintain theabsorbent web 408 in proper registration with the base web 494 as theweb segments 414 are cut from the web 494. The hold down device can be,for example, air-knife, vacuum covers, vacuum conveyor, ski, foldingboard, nip roll, fold finger, surface coatings, and/or side vacuumassist. The hold down device in the form of a vacuum conveyor 420 isillustrated in FIGS. 52 and 53. The illustrated vacuum conveyor 420comprising a vacuum chamber 422 and a conveyor belt 424 having aplurality of apertures 426 for allowing the vacuum to act on the web 494(i.e., both the base web 494 and the absorbent web 408). The aperturesare of appropriate size and distribution to act effectively on eachcontact element if cut, or the pattern is registered in the MD and CD tocontrol the contact elements.

In the illustrated embodiment, the discrete web segments 414 are placedon the perforated, continuous web 490 of fleece material atpredetermined spaced intervals. In one suitable embodiment, which isillustrated in FIG. 54, the web segments 414 are placed on the web 490such that web segments extends over the lines of weakness 405 formed inthe web by a predetermined distance D1. It is understood, that the websegments 414 can be placed on the web 490 in any suitable manner.

More specifically, the cutting and placing of segment 414 ismechanically linked to the perforating of continuous web 490 toestablish MD registration of the discrete web segment, the continuousweb and the slits 159, wherever they are applied. In one suitableembodiment, the assembly station 404 may include a vision/closed loopautomated or manual phasing system to ensure that the MD registration ofdiscrete web segment 414, the continuous web 490 and the slits 159 iswithin a predetermined tolerance. In one suitable embodiment, thetolerance of dimension D1 is within the range of 25 mm and 31 mm andmore suitably about 28 mm.

While still at the assembly station 404, each of the discrete websegments 414 is bonded (e.g., pressure bonded, thermal bonded,ultrasonically bonded, adhesively bonded) to the web 490. In theillustrated embodiment, for example, each of the web segments 414 isthermally bonded to the web 490. More specifically, the base web 494 ofeach of the web segments 414 is thermally bonded to the web 490 whilethe absorbent web 408 of each of the web segments is free from bonding.

In one suitable embodiment, which is illustrated in FIG. 55, the baseweb 494 of each of the segments 414 is thermally bonded to the web 490by feeding the base web 494 and the web 490, which is aligned with thebase web, through a nip 434 defined by a pair of spaced-part upper rolls436 and a lower roll 438. The upper rolls 436 are sufficiently spacedapart to allow the absorbent web 408 of each of the web segments 414 topass between the upper rolls. While the lower roll 438 is illustrated asbeing a single roll, it is understood that the lower roll could beformed as two separate spaced apart rolls similar to the upper rolls436.

As illustrated in FIG. 55, the assembly station 404 comprises anabsorbent web controller, indicated generally at 430, for positioningthe absorbent web 408 such that the base web 494 can be suitably bondedto the web 490. In the illustrated embodiment, for example, theabsorbent web controller 430 comprises a pair of rods 432 for pivotingthe absorbent web about its bonded end 410 to a generally perpendicularposition such that the free end 412 is spaced from the base web 494. Itis contemplated that the absorbent web controller 430 can be othersuitable web controllers including, but not limited to, proper tension,horizontal-straight-through webpaths, conveyors, vacuum conveyors,vacuum rolls, roll to roll transfer, air-knifes, skis, rotating discs,nip rolls, fold fingers, surface coatings, and/or side vacuum assist.Also is a requirement to control the contact elements once cut to ensurethey stay in their registered placement, are active and able to open tothe outside of the tampon and are undamaged. Any combination of the webcontrolling items listed above would be employed after the contactelements are cut in the web to maintain control throughout the process.

After the web segments 414 are bonded to the continuous web 490, asecondary bond 473 can be added to bond the absorbent web 408 to thebase web 498 (FIG. 54). In one suitable embodiment, the secondary bond473 is limited to an area or a portion of the area that will beoverlapped in the soft roll forming process, which is described in moredetail below. In such an embodiment and as illustrated in FIG. 54, thesecondary bond 473 would be disposed on the trailing side of the line ofweakness 405. Thus, the secondary bond 473 should be sufficient to bondthe absorbent web 408 to the base web 498. However, the secondary bond473 should not bond the base web 798 to the underlying web 490. Whilethe illustrated secondary bond 473 comprises point bonding, it isunderstood that any suitable bonding technique can be used to bond theabsorbent web 408 to the base web 498.

In one suitable embodiment, the assembly station 404 further comprisesan inspection system (e.g., one or more photo eyes), indicated generallyat 409 in FIG. 51, adapted to inspect one or more of the following—thelines of weakness 405 formed in the web 490 of fleece material, the cutsin the web 494 to form the discrete web segments 414, the placement ofthe web segments 414 on the web 490 of fleece material (e.g.,cross-machine direction alignment, machine direction alignment) and thebonding of the discrete web segments 414 to the web 490.

As mentioned above, the slits 96 in the absorbent web 408 of thediscrete web segments 414 can be preformed (i.e., formed before web 494is used as the supply roll 496) or formed during the manufacturing ofthe tampon 10. In an embodiment, the die cutting module is mechanicallylinked to the perforating cutters of the fleece and cover material andis phasable in order to maintain precise registration of the contactelements cuts and/or dead zones to the edges of the other materials.This could also be done via servo drives, phasing gearboxes, etc. In onesuitable embodiment wherein the slits 96 are formed during themanufacturing of the tampon 10, the web 490 having the discrete websegments 414 bonded thereto is fed from the assembly station 404 to adie cutting station 440 adapted to cut slits 96 in absorbent web 408.

In one suitable embodiment, the die cutting station 440 includes anabsorbent web controller, indicated generally at 442, for positioningthe absorbent web 408 such that the absorbent web can be suitably cut atthe cutting station to form the slits 96. The die cutting station 440 isoperable to cut slits in the folded portion of the web 494 of covermaterial, such as to form the slits 156 and corresponding contactelements 162 of the embodiment of FIG. 28. In an embodiment, the diecutting station 440 may be operable to cut the slits in a pattern inwhich a set of equally spaced slits is cut into the folded portions ofthe web 494 of cover material along a segment corresponding to thelength of cover material to be applied to a single pledget to form asingle tampon, followed by a relatively larger gap before the next setof equally spaced slits along a segment corresponding to the next lengthof cover material to applied to another pledget to form another tampon.

In another embodiment, which is illustrated in FIG. 41, the die cuttingstation 440 may be operable to cut the slits 156 such that each slit isequally spaced in the folded portions of the web of cover material alonga segment P1 corresponding to the length of cover material to be appliedto a single pledget to form a single tampon, followed by the next set ofequally spaced slits along a segment P2 corresponding to the next lengthof cover material to applied to another pledget to form another tampon.Thus, in this embodiment, each tampon 10 has the same number of contactelements 196 and each of the contact elements 196 has the same width Wand the same length L1. In the illustrated embodiment, for example, eachof the tampons 10 formed from the web 494 would have seven complete(i.e., whole) contact elements 196. It is understood, however, thatnumber of contact elements 196 per tampon 10, the width W of each of thecontact elements, and length L1 of each of the contact elements candiffer.

In the embodiment illustrated in FIG. 56, the absorbent web controller442 comprises a pair of support rods 444 for holding the absorbent web408 in a generally perpendicular position such that the free end 412 ofthe absorbent web is spaced from the base web 494 and can be acted on asuitable cutting device (e.g., a knife roll 446 and anvil roll 448 asillustrated in FIG. 56). It is contemplated that the absorbent webcontroller 442 can be other suitable web controllers including, but notlimited to, proper tension, horizontal-straight-through webpaths,conveyors, vacuum conveyors, vacuum rolls, roll to roll transfer,air-knifes, skis, rotating discs, nip rolls, fold fingers, surfacecoatings, and/or side vacuum assist. Also is a requirement to controlthe contact elements once cut to ensure they stay in their registeredplacement, are active and able to open to the outside of the tampon andare undamaged. Any combination of the web controlling items listed abovewould be employed after the contact elements are cut in the web tomaintain this control throughout the process (especially through thestringing module and into the soft winding station). The die cuttingstation can include a suitable inspection system (e.g., one or morephoto eye) for ensuring that the slits 96 are properly cut in theabsorbent web 408.

As seen in FIG. 51, the apparatus 400 comprises a withdrawal aidplacement station 500 having a suitable supply source 502 of acontinuous supply of string 504 (or other suitable withdrawal aidmaterial) suitable for use as the withdrawal aid 14 of the tampon 10. Asillustrated in FIG. 57, the string 502 can be cut and wrapped around theweb 490 at a predetermined located spaced from the discrete web segments414. More specifically, a cut portion 506 of the string 502 is wrappedaround the web 490 at a predetermined distance D2 from a leading edge ofthe web segment 414. In one suitable embodiment, the distance D2corresponding to the distance between the string 502 and leading edge ofthe web segment 414 is approximately equal to the distance D1corresponding to the distance between the line of weakness 405 formed inthe web 490 and a trailing edge of the web segment. It is understoodthat the distances D1, D2 can be different. For example, in theillustrated embodiment, the string 504 can be located approximately170.7 mm forward from the trailing line of weakness 405. In other words,the string 504 can be located at a location approximately two-thirds thedistance between adjacent leading and trailing lines of weakness 405. Inother words, the string 504 is registered in both the CD and MDdirections.

As seen in FIG. 57, the cut portion 506 of the string 502 wrapped aroundthe web 490 extends beyond the web and is positioned such that both endsof the cut portion are generally adjacent each other. The part of thecut portion 506 extending beyond the web 490 is rolled and/or tied toform the knot 444 in the withdrawal aid 14 of the tampon 10. In onesuitable embodiment, an inspection system (e.g., one or more photo eyes)is provided at the withdrawal aid placement station 500 to ensure, forexample, that the cut portion 506 of the string 502 is located properlyrelative to the web segment 414 and/or that the knot 444 is properlyformed.

After the part of the cut portion 506 extending beyond the web 490 istied, the web is conveyed by a ribbon transport device 510 (e.g., upperand lower spaghetti conveyors) to a suitable winding and sealing device,indicated generally at 520. In the embodiment illustrated in FIG. 51,the ribbon transport device 510 is a pair of opposed conveyors. In onesuitable embodiment, the opposed conveyors may employ metal fingers tomove the main ribbon. Suitably, the metal fingers of the opposedconveyors are MD registered to inhibit damage to the contact elements.The winding and sealing device 520 is configured to separate the web 490about the line of weakness 405 into individual units as the web is beingfed to the winding and sealing device. Each of the individual unitscorresponds to a single tampon 10.

After being separated from the web 490, each of the units is manipulated(e.g., rolled or folded) to form a softwind wherein the fleece materialdefines the core and the cover overlies and covers the fleece materialsuch as illustrated in FIG. 25. In this embodiment, however, the coveris carrying the absorbent web 408 having the plurality of slits 96,which are provided to form the contact elements 196 of the tampon 10.

As the soft wind process begins, a secondary absorbent tucker apparatus(not shown) can be used to ensure the absorbent web 408 is tucked into asoft wind cup and to maintain parallelism through the winding processwithout damaging the contact elements 196. The wind process needs to beMD registered and timed to complete its operation during the winderdwell time. As a result, predictable and repeatable angular rotation ofthe softwind cups from loading through each dwell point through ejectionis required.

A cover to cover sealing device 522 is provided to seal the overlappingportions of the web segments 414 (FIG. 51). More specifically, theportion of the base web 494 defining the cover of the tampon 10 isoverlapped upon itself and heat sealed along the overlap. In onesuitable embodiment, the overlap generally corresponds to the distanceD1 between the trailing edge of the web segment 414 and the line ofweakness 405 formed in the web 490. It is understood, however, cover canbe sealed using any suitable technique and that the cover can have othersuitable overlaps. It is also understood that the cover can be free fromoverlap (e.g., when the cover is sealed end-to-end). Suitably, the sealis sufficient to withstand the further processing and use.

In one suitable embodiment, the cover to cover sealing device 522 can beMD registered and timed to act during the soft wind dwell time. Thecover-to-cover bond of the web segment 414 can be a continuous bondpattern or several different bond points acting with different patterns,pressures, and temperatures. This bond could also be registered in torelation with the angular position of the winding forks in each windingcup. Additionally, back pressure from the winding forks may be needed toensure reliable seal.

Concentric ejecting and receiving transfer points aid in minimizingdamage and misalignment of the absorbent web 408 during transfer of thesoft wind. It is contemplated that the contact surfaces of the transferpoints may be tapered, coated, patterned to inhibit misalignment anddamage of the absorbent web. These may be CD or MD registered relativeto the contact element locations, cover to cover sealing and geometryfeatures of the compressor.

As noted above, the individual units can also be stacked, folded orotherwise manipulated into the softwind. For example, suitable menstrualtampons may include “cup” shaped pledgets like those disclosed in U.S.Publication No. 2008/0287902 to Edgett and U.S. Pat. No. 2,330,257 toBailey; “accordion” or “W-folded” pledgets like those disclosed in U.S.Pat. No. 6,837,882 to Agyapong; “radially wound” pledgets like thosedisclosed in U.S. Pat. No. 6,310,269 to Friese; “sausage” type or “wad”pledgets like those disclosed in U.S. Pat. No. 2,464,310 to Harwood;“M-folded” tampon pledgets like those disclosed in U.S. Pat. No.6,039,716 to Jessup; “stacked” tampon pledgets like those disclosed inU.S. 2008/0132868 to Jorgensen; or “bag” type tampon pledgets like thosedisclosed in U.S. Pat. No. 3,815,601 to Schaefer.

A suitable method for making “radial wound” pledgets is disclosed inU.S. Pat. No. 4,816,100 to Friese. The radial winding method can alsoinclude a method for forming the blank into a pledget like thatdisclosed in U.S. Pat. No. 6,310,269 to Friese. Suitable methods formaking “W-folded” pledgets are disclosed in U.S. Pat. No. 6,740,070 toAgyapong; U.S. Pat. No. 7,677,189 to Kondo; and U.S. 2010/0114054 toMueller. A suitable method for making “cup” pledgets and “stacked”pledgets is disclosed in U.S. 2008/0132868 to Jorgensen.

The softwind is then pushed from the winding and sealing device 520 by asuitable push rod (not shown) into a cup 528 of an articulating arm,indicated generally at 530 (FIG. 38). As illustrated in FIG. 51, thearticulating arm 528 transport the softwind from the winding and sealingdevice 520 to a compression station, indicated generally at 540. Morespecifically, a push rod (not shown) pushes the softwind from the cup528 of the articulating arm 530 into one of a plurality of mold cavities542 formed in a compressor of the compression station 540.

CD registration in the articulating arm 530 is established by eject armstroke length or stop points in the arm. The articulating arm 530 isused to bring the soft wind from the winding and sealing device 520 tothe compression station 540 in a repeatable and predictable angularposition. In order to achieve a desired angular position, thearticulating arm 530 may be capable of rotating the soft wind whiletransferring it. This may be controlled by inspection stations before,during, and or after transportation of the soft wind. Concentricejecting and receiving transfer points aid in minimizing the damage andmisalignment of the absorbent web 408 during transfer of the soft wind.Additionally, the contact surfaces of the transfer points may betapered, coated, patterned to prevent misalignment and damage and theabsorbent web 408. The ejection process (i.e., the process of removingthe soft wind from the cup 528) is controlled to register the soft windin the CD in the articulating arm 530. Additionally, the articulatingarm 530 can be capable of rotating the soft wind 180 degrees to reversethe nose and string end of the tampon.

During exit of the soft wind from the articulating arm 530 to one ofmold cavities of the compressor of the compressor station 540, CDregistration is controlled by the push length of the ejecting apparatusand/or stop points in the compressor. The angular position of the softwind (i.e., the position about the circumference of the soft wind)established by the articulating arm 530 is maintained, such as, by guiderails as the soft wind enters the compressor. The compressor geometrycan be such that in the open position there is oversized clearance ortapered, coated, patterned surfaces to protect the absorbent web 408during CD transport into the compressor. It is contemplated that theejecting apparatus can be adapted to rotate the soft wind in addition toor instead of the articulating arm 530.

The compressor (e.g., compressive jaws of the compressor) can have anysuitable pattern to facilitate compression of the soft wind whilemaintaining the integrity of the absorbent web 408 including the contactelements. For example, the compressive jaws can have a continuouspattern that varies in the CD direction and/or its annularity. Forexample, the compressive can vary in actuation depth or can have relief(i.e., a cutout) to accommodate the absorbent web 408 and, moreparticularly, the contact elements during the compression of the softwind. It is contemplated that the compressive jaws can be arranged toact on the contact elements and/or slits in the absorbent web 108, canbe arranged not to act on the contact elements and/or slits, or acombination thereof.

In one suitable embodiment, when the softwind is positioned within oneof the mold cavities of the compression station 540, a plurality of diesmoves towards one another and compress the softwind. In some suitableembodiments, the compression station 540 is adapted to apply heat to thesoftwind. The softwind can be compressed any suitable amount. Forexample, the softwind may be compressed at least about 25%, 50%, or 75%of the initial dimensions. For example, the softwind can be reduced indiameter to approximately ¼ of the original diameter. Thecross-sectional configuration of the resultant tampon 10 may becircular, ovular, rectangular, hexagonal, or any other suitable shape.

The compressed soft wind (i.e., the pledget) exits the compressor of thecompression station 540 into one of a plurality of holding tubes. CDregistration of the pledget is controlled and the angular position ofthe pledget (i.e., the position about the circumference of the pledget)established by the articulating arm 530 is maintained as the pledgetenters the respective holding tube.

A suitable nose forming apparatus (not shown) of the compression station540 forms the nose of the pledget. Thus, the location of the pledgetwithin the holding tube must be concentric predictable, and repeatable.In one suitable embodiment, the location of the pledget within theholding tube can be accomplished via mechanical linkages.

Once formed, the tampons 10 are pushed from the mold cavities 542 of thecompression station 540 by a push rod (not shown) in to a suitablewrapper at a wrapping and sealing station, indicated generally at 550,for sealing the tampons. The wrapping and sealing station 550 isconfigured to wrap each of the tampons 10 in the wrapper and to seal thewrapped. After the tampons 10 are wrapped and sealed in the wrapper atthe wrapping and sealing station 550, the tampons can be packaged forsale (i.e., placed in boxes suitable for sale to consumers). It iscontemplated that the tampons 10 can be placed into suitable applicators(not shown) prior to being wrapped and sealed at the wrapping andsealing station 550.

During the transfer of the softwind from the winding and sealing device520 to the cup 528 of an articulating arm 530 (which is illustrated inFIG. 58) and/or the transfer of the softwind from the cup of thearticulating arm into one of the plurality of mold cavities 542 formedin the compression station 540, a transfer assist device, indicatedgenerally at 560 in FIG. 58, facilitates the transferring for thesoftwind while maintaining the proper positioning of the portion of theabsorbent web 408 forming the softwind relative to the portion of thebase web 494 forming the softwind. In one suitable embodiment, thetransfer assist device 560 is a tapered guide 562 adapted to direct thetampon 10 into the cup 528 or the respective mold cavity 542 (the cup528 being seen in FIG. 58). More specifically, the tapered guide 562 isadapted to direct the free end 412 or bonded end 410 (depending on thedirection the softwind is being pushed and the direction in which thefree end and bonded end are oriented) into the cup 528 or respectivemold cavity 542 while inhibiting the portion of the absorbent web 408forming the softwind from becoming misaligned (e.g., wrinkled, creased,folded) with respect to the portion of the base web 494 forming thesoftwind. It is understood that the transfer assist device 560 can beother types of suitable devices including, for example, an air-knife,vacuum covers, vacuum conveyor, ski, folding board, nip roll, foldfinger, surface coatings, and/or side vacuum assist.

It is contemplated that once the contact elements are formed in the webof cover material, air flow (e.g., shielding, hold down devices,deflectors, vacuum) can be used to avoid disruption of the contactelements as the web of cover material is moving through the process. Itis also contemplated that static energy and humidity can be controlledthrough all or portions of the process. Static energy, for example, canbe controlled using de-ionizing bars, static eliminators, grounding“tinsels,” or other suitable grounding techniques.

In the interests of brevity and conciseness, any ranges of values setforth in this disclosure contemplate all values within the range and areto be construed as support for claims reciting any sub-ranges havingendpoints which are whole number values within the specified range inquestion. By way of hypothetical example, a disclosure of a range offrom 1 to 5 shall be considered to support claims to any of thefollowing ranges: 1 to 5; 1 to 4; 1 to 3; 1 to 2; 2 to 5; 2 to 4; 2 to3; 3 to 5; 3 to 4; and 4 to 5.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

All documents cited in the Detailed Description are, in relevant part,incorporated herein by reference; the citation of any document is not tobe construed as an admission that it is prior art with respect to thepresent invention. To the extent that any meaning or definition of aterm in this written document conflicts with any meaning or definitionof the term in a document incorporated by references, the meaning ordefinition assigned to the term in this written document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method of manufacturing a tampon comprising:transporting a web of material in a machine direction, the web ofmaterial comprising a base web for defining a cover material of thetampon and an absorbent web, the base web having opposing longitudinallyextending side edges, the absorbent web having a free end and a bondedend wherein the bonded end is bonded to the base web, the free end andbonded end of the absorbent web being disposed inward from the sideedges of the base web such that the entire absorbent web overlies and iscarried by the base web, the free end including a plurality of slitsextending in a cross-machine direction; controlling at least the freeend of the absorbent web of the web to inhibit movement of the absorbentweb relative to the base web; cutting the web of material in the crossmachine direction to form discrete web segments while controlling atleast the free end of the absorbent web; and bonding the discrete websegments to a substrate.
 2. The method set forth in claim 1 whereincontrolling at least the free end of the absorbent web of the webcomprises controlling at least the free end of the absorbent web using ahold down device.
 3. The method as set forth in claim 2 whereincontrolling at least the free end of the absorbent web using the holddown device comprises controlling at least the free end of the absorbentweb using at least one of an air-knife, vacuum covers, vacuum conveyor,ski, folding board, nip roll, fold finger, surface coatings, and sidevacuum assist.
 4. The method as set forth in claim 1 wherein bonding thediscrete web segments to the substrate comprises bonding the discreteweb segments to a continuous web of fleece material.
 5. The method asset forth in claim 4 further comprising transporting the continuous webof fleece material in the machine direction and aligning the continuousweb of fleece material with the base web.
 6. The method as set forth inclaim 5 further comprising bonding the base web of the discrete websegments to the continuous web of fleece material.
 7. The method as setforth in claim 1 further comprising inspecting the substrate having thediscrete web segments bonded thereto.
 8. The method as set forth inclaim 1 further comprising registering a string with the substrate, thestring being spaced from the discrete web segments.